A research team from the University of Texas at Dallas (UTD) has developed a 3D-printed femur model, potentially paving the way for cost-effective and customizable solutions in orthopedic surgery preparation, biomechanical studies, and bone repair. Created through a collaboration with UT Southwestern Medical Center’s orthopedic surgeons, this 3D-printed femur represents a new approach to improving surgery planning and training with a patient-specific focus.

Challenges in Traditional Bone Surgery Preparation

In traditional practice, orthopedic surgeons rely on cadaver bones or synthetic bone models to study surgical techniques and evaluate the effectiveness of implants. However, cadaver bones are expensive and difficult to source, and commercially available synthetic bones may lack the anatomical precision needed for customized treatment. Additionally, they can take time to acquire and may not reflect the unique geometry required for patient-specific procedures.

Led by Dr. Wei Li, assistant professor of mechanical engineering at UTD, the research team designed a 3D-printed femur prototype made from polylactic acid (PLA), a biodegradable polymer widely used in 3D printing. This material allows for cost-effective production, with each femur model costing around $7 to print. At nearly eight inches in length and one inch in diameter, the printed bone represents the midsection of a human femur and demonstrates mechanical properties closely aligned with natural human bone in lab testing.

femur samples

Researchers produced femur samples using a 3D printer, estimating a production cost of approximately $7 per femur model. (Image Credit: UTD)

The 3D printing process enables engineers to replicate the precise geometry of a patient’s femur, potentially allowing doctors to customize models to fit individual patients. This capability could be essential in bone tumor treatment, where replicating affected bone sections could aid in testing targeted therapies.

Applications and Future Directions

Beyond providing a cost-effective alternative for biomechanical studies and surgical training, the 3D-printed femur has broader implications. Dr. Li suggests that the polymer model could one day replace materials like titanium currently used in bone repair. In another promising application, researchers plan to incorporate 3D-printed tumors into these models, allowing for preoperative testing and treatment development directly on simulated bone structures.

This project has brought together experts from different disciplines, including orthopedic oncology surgeon Dr. Robert Weinschenk and hand and upper extremity surgeon Dr. Richard Samade from UT Southwestern. Both surgeons bring engineering expertise to the project, enhancing the collaborative approach in exploring novel orthopedic solutions.

The promising results from this study, published in the Journal of Orthopaedic Research, highlight the potential for 3D-printed bones to advance orthopedic care. Further research will refine the models and explore additional clinical applications, including potential use in bone tissue regeneration.

As the research progresses, the UTD and UT Southwestern teams are optimistic about how 3D printing can transform orthopedic surgery and enable more personalized and precise treatments.