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Facial contouring and reconstructive surgery

Patient-specific PEEK contour implants

Chin, mandibular angles and contour, cheekbones, paranasal region and orbit. The shape is designed from the CT and agreed before surgery.

PEEK midface contour implant on a skull model
PEEK contour implant — manufactured from the patient's CT
Applications by region

Where facial implants are used

Patient-specific geometry from CT for different facial regions. The region, volume and approach are chosen by the surgeon.

Chin region
Chin / Projection and shape based on individual anatomy
Mandibular angles
Mandibular angles / Volume, contour and symmetry of the lower third
Mandibular contour
Jawline / A single geometry from the angle to the chin
Zygomatic region
Cheekbones / Zygomatic and zygomatico-orbital regions
Paranasal region
Paranasal region / Midface volume and support
Orbital region
Orbit / Orbital plates, orbital walls and floor
Aesthetic cranioplasty where indicated is a separate task and is discussed on the basis of the CT data. The applicability of each region depends on the anatomy, the soft tissues and the surgical plan.
How PEEK makes the surgeon's work easier

Shape controlled before surgery

The implant volume and position are designed from the CT, keeping intraoperative adjustment to a minimum.

  • The shape is agreed in advance; revisions are made at the 3D model stage
  • PEEK is radiolucent — convenient follow-up and symmetry assessment
  • The result can be shown to the patient before the procedure
PEEK mandibular contour implant
Contour implant for the mandibular body and angle on an anatomical model
Zygomatic contour implants on an anatomical model
Device

Symmetry is built into the geometry

Paired regions are designed in a single coordinate system — the implant restores the bone contour rather than masking it.

Visual demonstration

Devices on the anatomy

Midface contour implants on models
Midface / Implants on anatomical models
Mandibular contour implant on a model, held in hand
Implant in hand / Fit verification on the model
Mandibular contour implant, lateral view
Mandibular contour
Midface contour implant on a maxillary model
Nasozygomatic region
Mandibular angle implant
Mandibular angles
3D visualisation of the chin implant for approval
3D visualisation of the shape for discussion with the patient before surgery
Talking with the patient

Show the outcome before surgery

3D visualisation of the implant and soft tissues, an anatomical model and the device itself — arguments you can show and put in the patient's hands.

  • “Before” and “after” are visible on the 3D model
  • A clear explanation: where the implant sits and where it is fixed
  • A joint decision — less uncertainty
How the process works

From CT to device

CT segmentation
01 / CT and clinical task / MSCT using the facial protocol
Implant modelling
02 / Modelling / Implant and soft tissue
Shape approval
03 / Approval / With the surgeon and the patient
Printing the PEEK implant
04 / PEEK printing / On modern equipment
Finished implant on the model
05 / Delivery / Implant and anatomical models — delivered to the clinic
Tone of communication: we do not promise a guaranteed clinical outcome. A PEEK implant is a controllable tool; the final decision and the assessment of applicability remain with the surgeon.
When it is used

Indications for patient-specific implants

Patient-specific implants are indicated when standard methods (lipofilling, osteotomies, off-the-shelf plates) do not deliver a predictable aesthetic and functional result.

Post-traumatic deformities

Midface and lower third of the face after trauma.

Congenital anomalies

Developmental anomalies of the facial skeleton.

Secondary correction

After failed surgeries.

Defects after oncological resections

Volume restoration after resections.

Complex asymmetries

Requiring precise volumetric correction.

The case in numbers

When it matters that the patient sees the result before surgery.

Comparison of solutions

Approaches to facial contour correction

Contouring can be addressed in different ways, from soft tissue procedures to patient-specific implants. The surgeon chooses the method and material according to the clinical situation.

MethodSummaryKey features
FillersSoft tissue treatment, without surgeryA temporary effect requiring repeat procedures; they do not restore bone contour
Bone graftingVolume restoration with the patient's own tissueMore invasive; partial graft resorption is possible
Medpor (porous polyethylene)Porous implant, tissue ingrowthOff-the-shelf shapes, adjusted intraoperatively; removal is difficult
SiliconePreformed implantA capsule forms; it does not integrate with tissue
PEEK (patient-specific)High-strength, produced from the CT and 3D planPatient-specific geometry, radiolucency, shape approved before surgery

This summary is general in nature; data on risks and complications can be found in the literature at the end of the page. The applicability of each method depends on the anatomy, the soft tissues and the surgical plan.

How to start

A clear route: physician → patient → CT → device

No scattered instructions in chats — your case is assigned a dedicated support engineer and a step-by-step workflow.

01

Discuss your case

Send us the task and an engineer will advise on applicability and a possible solution.

02

Show it to the patient

3D visualisation and a model for approval — the patient sees the result in advance.

03

Send us a CT scan

Following the protocol, an engineer builds an accurate implant model.

04

Approve and order

Revisions before manufacturing, then printing and delivery of the kit to the clinic.

Personal support. An engineer supports your case at every step — helping with BonaPlanner onboarding and the first implantation. The support engineer is part of the product, not just “instructions in a chat”.
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

The construct is manufactured to the agreed plan: the physician approves the 3D fit, volume and position before manufacturing, and revisions are made at the model stage. Prior 3D planning makes the shape and fit of the device more predictable; the final result depends on the clinical situation and the course of surgery.

With a correct CT protocol and the design agreed before manufacturing, the amount of intraoperative adaptation can be reduced — the shape and fit are calculated in advance from the CT. Decisions during surgery remain with the surgeon.

A 3D model of the implant and the soft tissues is built from the CT; if required, an anatomical model and a mock-up of the implant are produced. This helps the physician discuss the planned solution with the patient. Bonabyte does not replace an in-person consultation and does not guarantee a clinical outcome.

Patient-specific PEEK is designed from the CT for the individual anatomy: the shape and position are agreed in advance, without reshaping off-the-shelf forms during surgery; PEEK is radiolucent and compatible with CT/MRI. PEEK may be preferable for patient-specific bone contouring where precise geometry, fixation to the CT plan and prior approval of the shape matter. The choice of material and method rests with the physician.

Your case is assigned a dedicated support engineer: a step-by-step route “physician → patient → CT → order”, help with the first case and with BonaPlanner onboarding — without scattered instructions in chats.

When restoring the bone contour, symmetry and stable volume to an individual plan matters, this is a different task from soft tissue techniques. The physician chooses the approach and method according to the clinical situation.

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
  • build a 3D model of the facial skeleton from the CT
  • design a contour implant matched to the anatomy
  • agree the shape and volume with the surgeon before manufacturing
  • manufacture a PEEK device
What we cannot determine without the physician and the source data
  • the medical indications for the procedure
  • surgical access
  • soft tissue condition
  • the aesthetic outcome based on computer visualisation
  • the prognosis of the clinical outcome
Related solutions

What else you may need

Shall we discuss a contouring case?

Send us a CT — an engineer will model the implant and the soft tissues and show the planned result before surgery.

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. Kurtz SM, Devine JN. PEEK biomaterials in trauma, orthopedic, and spinal implants. Biomaterials. 2007;28(32):4845–4869. [source]
  2. Porous polyethylene (Medpor) implants in facial reconstruction: outcome and complications. J Craniomaxillofac Surg. 2015. [source]
  3. Facial reconstruction using porous high-density polyethylene (Medpor): long-term results. J Plast Reconstr Aesthet Surg. 2012. [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.