Additive manufacturing has enabled a radical change in how surgeons reconstruct massive acetabular defects in revision hip surgery. We report on the early clinical and radiological results from our methods for surgical planning, design, and implantation of 3D printed trabecular titanium implants in a cohort of patients with large unclassifiable pelvic defects.

We set up a prospective investigation involving 7 consecutive patients. Inclusion criteria was the following: 1) A history of previous total hip replacement; and 2) Current imaging showing at least a Paprosky 3B defect. Planned acetabular inclination and version was 40° and 20° respectively. Post operatively all patients had a CT scan which was analysed with software to determine component position and compared to planned. Outpatient review was done at 2 weeks (For wound), 6 weeks (for weight bearing and fixation) and 52 weeks (for fixation and infection) post-operative.

The median age at surgery was: 65 years (40–78). The median bone defect volume was 140cm³. Median surgery length was 5.2 hours (3–6.25). Median blood loss was 1300mL (450– 2000). Radiologically, components were stable and no screw breakages were identified. Achieved inclination was 41.0° (29.0–55.6) and achieved version was 15.8° (3.8–43.6). Median Oxford Hip score improved from 9 (2–44) to 25 (18–32).

We have demonstrated a new series of pre, intra and post-operative methods for reconstruction of unclassifiable acetabular bony defects. Initial clinical and radiological results are excellent considering the severity of the bony defects. We recommend the use of our or similar methods when trying to reconstruct these defects.