Researchers at UT Dallas have introduced a groundbreaking 3D-printed femur that could transform bone repair surgeries and tumor treatment. This innovative, cost-effective solution has the potential to revolutionize orthopedic medicine.
Mechanical engineers at The University of Texas at Dallas have created an innovative 3D-printed femur that promises to enhance surgical preparation and develop more effective treatments for bone tumors. This breakthrough, a collaborative endeavor with orthopedic surgeons at UT Southwestern Medical Center, has been published in the Journal of Orthopaedic Research.
The study focuses on precise 3D-printing parameters for the femoral midsection, establishing a framework for the artificial bone to be used in biomechanical testing. While the technology showcases significant promise, further studies are necessary before it becomes a staple in medical practice.
In traditional methods, surgeons rely on cadavers or commercially available synthetic bones for biomechanical research and surgical training. However, these resources can be costly, difficult to obtain, and lack customization for individual patients.
Seeking a more efficient alternative, UT Southwestern researchers, including orthopedic oncology surgeon Robert Weinschenk and hand surgeon Richard Samade, partnered with Wei Li, an expert in 3D printing at UT Dallas.
“To make plans for surgery, surgeons need to know the geometry of the bone,” Li, an assistant professor of mechanical engineering in the Erik Jonsson School of Engineering and Computer Science and corresponding author of the study, said in a news release. “With 3D printing, we’re able to print out the femur bone sample with the same geometry of the femur inside the body.”
UT Dallas doctoral student Kishore Mysore Nagaraja spearheaded the development of the femur replicas in Li’s Comprehensive Advanced Manufacturing Lab. He conducted a series of tests to ensure the artificial bones’ mechanical performance and material properties closely mirrored those of real femurs.
“This collaborative experience is the best thing a student could ask for,” Mysore Nagaraja, who is set to graduate in December, said in the news release. “To get an evaluation of my testing research directly from the doctors who are going to use it is a very good validation of our research.”
Made from polylactic acid — a bio-based, biodegradable polymer — the 3D-printed femur measures almost 8 inches in length and approximately 1 inch in diameter. Impressively, the cost to produce each femur stands at just $7, and their biomechanical properties have proven comparable to human femurs.
Further applications of this technology appear promising, with the 3D-printed polymer possibly replacing conventional bone repair materials like titanium. Additionally, Li envisions the potential to print tumors on these femur models to test treatments, or even use these replicas to grow human bone tissue in the future.