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Neurosurgery

Patient-specific cranioplasty: PEEK and titanium

A cranial plate that follows the patient's cranial vault based on the CT data. Manufacturing from 4 business days after approval.

Patient-specific cranial plate in a cranial vault model
Patient-specific cranial plate trial-fitted in an anatomical cranial vault model
What it is

The plate restores the patient's anatomy

We reconstruct the geometry from the CT — by mirroring the healthy side or reconstructing the curvature of the vault. The surgeon approves the shape, thickness and fixation before manufacturing.

  • An anatomical fit to the defect — with no intraoperative reshaping
  • A surgical guide and an anatomical model are included
  • A PEEK plate can be adjusted during surgery
  • Manufacturing from 4 business days after approval
Patient-specific perforated PEEK cranial plate on a cranial vault model
Perforated PEEK cranial plate on a cranial vault model
Two materials

PEEK or titanium — depending on the clinical task

Perforated PEEK cranial plate on the model
PEEK — radiolucency / An elastic modulus closer to bone, convenient imaging follow-up, variable thickness
Patient-specific titanium cranial plate with a mesh structure
Titanium — strength and osseointegration / Lightweight mesh structures, thin devices for large defects

A detailed comparison of PEEK · titanium · PMMA is in the technical section below.

Patient-specific cranial plate on an anatomical model
Device

The plate curvature and thickness required for the patient

Every plate is designed for the specific defect and checked on an anatomical model before shipment.

Visual demonstration

Devices on the anatomy

Cranial plate fitted into a skull model
Plate in a skull model
Verifying the cranial plate fit on a skull model
Fit verification on the model
Cranial plate with a large-cell structure on the model
Large-cell titanium structure
How it is made

From CT to the finished plate

3D skull model with the defect, built from the CT
01 / CT and 3D model / Segmentation, defect model
Virtual cranioplasty planning
02 / Planning / Geometry and mirroring
Design of the patient-specific implant
03 / Device design / Thickness, contour, fixation
Manufacturing: SLM printing
04 / Manufacturing / After approval by the physician
Finished plate: fit verification
05 / Fit verification / Trial fit on the model, delivery
Device examples

Bonabyte cranial plates

PEEK plate
PEEK plate
Cranial plate in a cranial vault model
Cranial plate in a cranial vault model
The curvature follows the cranial vault
The curvature follows the cranial vault
Titanium plate
Titanium plate
Fit verification against the defect
Fit verification against the defect

Bonabyte device photographs and 3D renders. Manufactured individually from the patient's CT.

Material selection

PEEK · Titanium · PMMA

PEEK, titanium and PMMA (bone cement) are used for cranioplasty. The choice is driven by the clinical task; the decision is made by the physician.

CriterionPEEKTitaniumPMMA
RadiolucencyRadiolucent; usually makes postoperative imaging follow-up easierRadiopaque, artefacts are possibleHigh
StrengthHighVery highMedium
OsseointegrationLowHigher; porous SLM structuresLow
ManufacturingPatient-specific, based on CTPatient-specific, based on CTIntraoperatively or using a patient-specific guide

Summary data on complications and outcomes (including a comparison of PEEK and titanium) can be found in the literature at the end of the page. The choice depends on the clinical task: defect size, the need for imaging follow-up and loading.

BonaPlanner · overall scene

Planning and postoperative follow-up

Procedure simulation

Building the implant from the CT, with bone and implant contours shown on the slices.

Selection of fixation hardware

Fixation points and screws are planned in advance.

Postoperative superimposition

Comparing plan with outcome and assessing the fit after surgery.

Patient-specific titanium cranial plate
The plate curvature follows the patient's own cranial vault
Documents and CT requirements

Download the protocol and materials

A correct CT scan speeds up planning and reduces rework. Download the protocol for this speciality and include a link to the DICOM when you send it.

FAQ

FAQ

PEEK is radiolucent and usually makes postoperative imaging follow-up easier than metal constructs; it provides an anatomical fit based on the CT, and its thickness can be varied to match the bone. Titanium offers strength, lightweight mesh structures, osseointegration and the manufacture of both bulky and thin devices. The choice of material is determined by the clinical task and the physician's decision.

Manufacturing takes from 4 business days after the implant is approved. The engineer confirms the exact timeline after reviewing the CT and agreeing the design.

PEEK plates can be modified during surgery if necessary. Even so, the shape and fit are agreed in advance to keep intraoperative adjustment to a minimum.

MSCT with full coverage of the defect and the healthy contralateral side for mirroring, slice thickness 0.5–0.625 mm, increment ≤1 mm, gantry 0°, DICOM format. Details are in the CT protocols section.

What you should know

Limits of what is possible

Bonabyte designs and manufactures the device according to the treating physician's plan. Medical decisions are made by the surgeon.

What we can do
  • reconstruct the defect geometry from the CT
  • design a patient-specific cranial plate
  • agree the thickness, contour, perforation and fixation
  • manufacture a device from PEEK or titanium
  • provide an anatomical model or a guide, where the project calls for it
What we cannot determine without the physician and the source data
  • the medical indications for surgery
  • surgical access
  • whether a particular material is acceptable
  • the condition of the soft tissues and skin
  • the final fixation method
  • the prognosis of the clinical outcome
Related solutions

What else you may need

A complex cranial defect?

Send us a CT — an engineer will build the model, select the material (PEEK or titanium) and prepare the plate with a guide.

Sources and literature

Further reading on this topic

These publications are provided as a reference for professionals. They relate to the topic of this section and are not a guarantee of the outcome in any particular case; applicability is determined by the treating physician. The list should be reviewed and expanded by a clinical specialist.

  1. Personalized 3D-printed titanium and PEEK vs standard implants in cranial reconstruction: meta-analyses. Neurosurg Rev. 2025. [source]
  2. Outcomes following PEEK cranioplasty: systematic review and meta-analysis. J Clin Neurosci. [source]
  3. Complications following titanium vs non-titanium cranioplasty: systematic review and meta-analysis. 2021. [source]
  4. Kurtz SM, Devine JN. PEEK biomaterials in trauma, orthopedic, and spinal implants. Biomaterials. 2007;28(32):4845–4869. [source]

The information on this website is intended for healthcare professionals and does not constitute medical advice, a public offer or a guarantee of clinical outcome. Bonabyte devices are custom-made medical devices designed for a specific clinical task; their applicability depends on the CT data, the anatomy, the condition of the soft tissues, the surgical access and the operative plan. The final decision on the use of a device is made by the treating physician. Contraindications exist and an individual assessment of the clinical situation is required.