Patient-specific Ti-6Al-4V lattice implants for critical-sized load-bearing bone defects reconstruction

Amit Benady, Sam J. Meyer, Eran Golden, Solomon Dadia, Galit Katarivas Levy

Research output: Contribution to journalArticlepeer-review

7 Scopus citations


The advancement in additive manufacturing in recent years opened a new era for bone reconstruction methods, allowing for the design of customized implants that perfectly match clinical needs. This challenge is even more prominent in critical-sized bone defects, where the bone cannot heal independently. Here we present a novel workflow for such cases. First, a multidisciplinary team conducted the surgical plan, including the design of an intraoperative patient-specific instrument. Then, a Ti-6Al-4V implant was created to exactly fit the resected tumor's bone gap. An ambitious bone regenerative approach was taken in designing the implants with a porous-lattice body acting as a scaffold for new bone formation, reinforced with standard orthopedic instruments for adequate mechanical support. To prevent future failure of the implant, a finite element analysis was used to evaluate stress distribution simulation according to the multi-axis forces and moments applied on the bone during walking. Our results demonstrate the potential for Ti-6Al-4V implants to become the best practice for reconstructing significant bone defects. This proof-of-concept may enhance clinical care and catalyze new frontiers in patient-specific medicine. To the best of our knowledge, this is the first study to describe in detail the design and fabrication of this method.

Original languageEnglish
Article number111605
JournalMaterials and Design
StatePublished - 1 Feb 2023

ASJC Scopus subject areas

  • General Materials Science
  • Mechanics of Materials
  • Mechanical Engineering


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