Additive Manufacturing in Orthopaedic Trauma: Current Evidence and Applications
Abstract
1. Introduction
2. Methods
2.1. Study Design
2.2. Literature Search Strategy
2.3. Eligibility Criteria
2.4. Study Selection and Data Extraction
3. Results
3.1. 3D-Printed Anatomical Models
3.2. Patient-Specific Surgical Guides
3.3. 3D-Printed Implants
3.4. Temporary 3D-Printed External Fixation Devices
4. Discussion
5. Limitations
6. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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| 3D-Printing Application | Main Purpose in Trauma | Key Reported Benefits/Outcomes | Main Limitations & Barriers | Current Maturity/Evidence Strength |
|---|---|---|---|---|
| 3D-printed anatomical models | Preoperative planning and enhanced fracture understanding (patient-specific anatomy, fracture morphology) | Improved spatial understanding and surgical planning; increased surgeon confidence; reported reductions in operative time, blood loss, and intraoperative fluoroscopy use | Preparation time required for image segmentation and model production; institutional cost variability; may not be feasible in urgent trauma cases | Most established clinical application with multiple comparative clinical trauma studies |
| Patient-specific surgical guides (PSSGs) | Translate digital planning into accurate intraoperative execution (e.g., screw trajectory, osteotomy angles, entry points) | Improved screw positioning accuracy and alignment; reproducible entry points and trajectories; reduced need for intraoperative adjustments; reduced fluoroscopy use in selected procedures | Requires stable anatomical landmarks; affected by soft-tissue injury and swelling; preparation time and heterogeneous clinical evidence | Moderate clinical evidence derived from small cohorts and heterogeneous anatomical indications |
| 3D-printed patient-specific implants | Definitive reconstruction in complex defects (post-traumatic segmental bone loss, deformity, failed fixation) | Patient-specific implant geometry with porous titanium structures supporting implant integration and stability; favorable outcomes reported in small clinical series | Limited trauma-specific clinical data; manufacturing timelines; regulatory and certification requirements | Emerging clinical application supported by small clinical series and biomechanical studies |
| Temporary 3D-printed external fixation devices | Customizable temporary stabilization in staged trauma care | Potentially lower production cost and customizable designs; mechanical performance comparable to standard fixators in biomechanical studies | Evidence mainly limited to design and biomechanical feasibility studies; limited clinical validation | Early/experimental stage |
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Stavropoulos, N.A.; Kantas, F.; Papadopoulos, D.V.; Nikolaou, V.S.; Babis, G.C. Additive Manufacturing in Orthopaedic Trauma: Current Evidence and Applications. Medicina 2026, 62, 599. https://doi.org/10.3390/medicina62030599
Stavropoulos NA, Kantas F, Papadopoulos DV, Nikolaou VS, Babis GC. Additive Manufacturing in Orthopaedic Trauma: Current Evidence and Applications. Medicina. 2026; 62(3):599. https://doi.org/10.3390/medicina62030599
Chicago/Turabian StyleStavropoulos, Nikolaos A., Fotios Kantas, Dimitrios V. Papadopoulos, Vasileios S. Nikolaou, and George C. Babis. 2026. "Additive Manufacturing in Orthopaedic Trauma: Current Evidence and Applications" Medicina 62, no. 3: 599. https://doi.org/10.3390/medicina62030599
APA StyleStavropoulos, N. A., Kantas, F., Papadopoulos, D. V., Nikolaou, V. S., & Babis, G. C. (2026). Additive Manufacturing in Orthopaedic Trauma: Current Evidence and Applications. Medicina, 62(3), 599. https://doi.org/10.3390/medicina62030599

