OsteoFab® PEKK: Custom, Metal-Free Implants

Patient Specific Reconstruction without Metal

Complex skeletal defects of the skull, face, and extremities challenge even the most experienced reconstructive surgeons. Traditional titanium plates and meshes can restore shape but introduce limitations. Metallic implants create imaging artefacts, interfere with radiotherapy planning, and can become a source of infection or thermal sensitivity. OsteoFab® patient specific implants fabricated from PEKK polymer provide a fully custom solution that overcomes these drawbacks. By combining digital design with additive manufacturing, OsteoFab® delivers precision fit, biocompatibility, and long term stability without the presence of permanent metal.

Material Science – Why PEKK Matters

Polyetherketoneketone (PEKK) is a high performance thermoplastic with exceptional mechanical strength and chemical resistance. Its modulus of elasticity closely matches cortical bone, reducing stress shielding and improving load sharing. PEKK is naturally radiolucent, allowing post operative CT and MRI imaging without streak artefacts. The material is inert and has a long history of safe use in medical devices, showing excellent resistance to infection and thermal conductivity comparable to native bone. For surgeons, this means a material that behaves more like bone than metal while maintaining the structural reliability needed for demanding reconstructions.

Digital Design – From Scan to Implant

Each OsteoFab® implant begins with high resolution patient imaging. CT data are converted into a three dimensional model that captures the exact defect and surrounding anatomy. Using advanced CAD software, engineers collaborate with the surgeon to design an implant that restores form and function precisely. Open communication allows the surgical team to specify screw holes, surface texturing, and integration features. Virtual surgical planning sessions ensure the design meets both aesthetic and functional goals before manufacturing begins. This digital workflow eliminates guesswork and creates an implant that fits the first time.

Additive Manufacturing – Precision in Every Layer

OsteoFab® implants are produced using laser sintering technology that builds the PEKK polymer layer by layer. This additive approach makes it possible to create complex geometries, fine surface details, and patient specific contours that are impossible to achieve with traditional milling. The process is tightly controlled to ensure dimensional accuracy and mechanical integrity. Once printed, each implant undergoes meticulous finishing, cleaning, and sterilisation to meet the highest regulatory standards. Surgeons receive an implant that matches the approved digital model to sub millimetre precision.

Surgical Technique – Familiar Fixation with Improved Handling

Implantation of an OsteoFab® device follows standard reconstructive principles. After exposure of the defect and preparation of recipient bone edges, the custom PEKK implant is positioned using the pre planned orientation markers. Because the material is lightweight and easily drilled, surgeons can fine tune fixation using standard titanium screws without risk of splintering or cracking. The radiolucent property allows immediate intraoperative imaging to verify alignment without artefact, providing confidence before closure.

Clinical Outcomes – Proven Reliability

Multicentre studies and case reports demonstrate excellent outcomes in cranio maxillofacial reconstruction, limb salvage, and complex orthopaedic oncology. Surgeons report high patient satisfaction with contour restoration and long term stability. Follow up imaging confirms maintenance of shape and integration with surrounding tissues, while the absence of metallic artefacts enables accurate postoperative assessment and any necessary radiotherapy planning. Complication rates are low and comparable to or better than conventional metallic reconstructions.

Key Advantages for Surgeons and Patients

The core benefits of OsteoFab® technology can be summarised succinctly:

• True patient specific design for an exact anatomical fit

• Radiolucent material enabling clear CT and MRI imaging

• Mechanical properties close to cortical bone for natural load sharing

• Low infection risk and excellent biocompatibility

• No need for removal or concern about thermal sensitivity

These attributes reduce surgical time, simplify postoperative care, and improve both functional and cosmetic outcomes.

Broad Applications – From Craniofacial to Extremity Reconstruction

OsteoFab® implants are used in a wide range of procedures. In cranio maxillofacial surgery they restore large skull defects following trauma or tumour resection. In limb reconstruction they replace segments of bone lost to infection or malignancy. The ability to incorporate integrated fixation points and porous regions for soft tissue ingrowth makes them suitable for demanding orthopaedic cases where conventional hardware would be bulky or difficult to contour.

Economic and Practical Considerations

Although each implant is custom made, the digital workflow streamlines production and reduces operative time. The elimination of intraoperative contouring and the predictable fit can shorten theatre sessions and decrease overall cost of care. Radiolucency removes the need for specialised imaging protocols, saving time during follow up and allowing precise monitoring of adjacent tissues. Avoiding the need for future hardware removal further reduces long term expense.

Everyday Impact – Better Outcomes and Patient Satisfaction

Patients experience the tangible benefits of a lightweight implant that mirrors their anatomy. They avoid the cold sensitivity sometimes associated with metal plates and enjoy a natural appearance with minimal contour irregularity. Surgeons appreciate the ease of placement, the freedom to image without artefact, and the ability to plan future procedures without the constraint of retained metal. The combination of advanced material and digital design translates directly into improved quality of life for the patient.

Conclusion – Custom Reconstruction without Compromise

OsteoFab® PEKK implants bring together cutting edge imaging, precise engineering, and a biologically friendly material to create custom, metal free reconstructions. For surgeons seeking accuracy, strength, and long term stability without the limitations of titanium, PEKK represents a proven next generation solution. From the first CT scan to the final surgical outcome, OsteoFab® technology places patient specific design at the heart of modern reconstructive surgery.