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Objective <p>This study presents a novel approach to reconstructing a large defect in the load-bearing condylar region of distal femur following the surgical removal of a giant cell tumor (GCT). By using advanced 3D printing technology and virtual surgical planning, designing a patient-specific implant (PSI) to replace the defect and integrate a fibular graft for osseointegration, providing cortical bone strength.</p> Methods <p>A 40-year-old female patient with recurrent pain and swelling in the left knee was diagnosed with a distal femoral GCT. Imaging studies confirmed a large lytic lesion with cortical thinning. After tumor excision, reconstruction was performed using a 3D-printed lattice metal implant designed for biological and mechanical integration. A 3D printed custom titanium plate was used additionally for structural support and a fibular graft was embedded within the implant for biological union.</p> Results <p>Postoperative outcomes demonstrated progressive osseointegration, weight-bearing capability, and functional recovery. The patient regained maximum osseointegration with the completion of 6 months and full-strength unrestricted mobility at the end of 18 months postoperatively without recurrence. Radiographic follow-ups confirmed structural integrity and graft incorporation.</p> Conclusion <p>This study illustrates the successful application of a customized lattice metal implant integrated with a fibular graft, demonstrating its feasibility for large tumor-induced defects in weight-bearing regions.</p>

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Reconstruction of a large distal femoral giant cell tumor using a 3D-printed condylar support lattice metal implant and fibular grafts: a novel biomechanical and surgical approach

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年7月16日

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  • Aashish Chaudhry,
  • Abhishek Kumar Sambharia,
  • Bharat Bahre,
  • Mani Pandey,
  • Tanvi Chawla

摘要

Objective

This study presents a novel approach to reconstructing a large defect in the load-bearing condylar region of distal femur following the surgical removal of a giant cell tumor (GCT). By using advanced 3D printing technology and virtual surgical planning, designing a patient-specific implant (PSI) to replace the defect and integrate a fibular graft for osseointegration, providing cortical bone strength.

Methods

A 40-year-old female patient with recurrent pain and swelling in the left knee was diagnosed with a distal femoral GCT. Imaging studies confirmed a large lytic lesion with cortical thinning. After tumor excision, reconstruction was performed using a 3D-printed lattice metal implant designed for biological and mechanical integration. A 3D printed custom titanium plate was used additionally for structural support and a fibular graft was embedded within the implant for biological union.

Results

Postoperative outcomes demonstrated progressive osseointegration, weight-bearing capability, and functional recovery. The patient regained maximum osseointegration with the completion of 6 months and full-strength unrestricted mobility at the end of 18 months postoperatively without recurrence. Radiographic follow-ups confirmed structural integrity and graft incorporation.

Conclusion

This study illustrates the successful application of a customized lattice metal implant integrated with a fibular graft, demonstrating its feasibility for large tumor-induced defects in weight-bearing regions.