Home/Traumatology and orthopaedics
Reconstructive surgery

Traumatology and orthopaedics: patient-specific constructs, guides and bone defect reconstruction

We handle complex cases where an off-the-shelf construct does not fit the anatomy: the pelvis and acetabulum, revisions and corrective osteotomies. We do not manufacture a full catalogue of standard trauma implants.

Patient-specific acetabular component
Acetabular prosthesis — SLM-printed titanium
Devices and renders

Patient-specific constructs for traumatology

Acetabular component on the model
Acetabular component on the model
Porous structure of the component
Porous structure of the component
Ti-6Al-4V plates and fixation
Plates for restoring limb function
Porous tibial cone
Porous tibial cone
Porous wedges
Porous wedges

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

What we manufacture

What Bonabyte designs for traumatology and orthopaedics

We handle cases where no off-the-shelf size fits the defect.

Patient-specific acetabular component with a porous structure on the model

Acetabular components

Patient-specific cups for the acetabular defect, with a porous structure for osseointegration.

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Patient-specific component with an augment, porous structure

Augments

Reconstruction of bone defects in revision cases and complex anatomy.

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Patient-specific acetabular components in various configurations
Revision cases / Constructs designed for the specific defect following previous surgery.

Revision cases

Constructs designed for the specific defect following previous surgery.

Patient-specific plate on an anatomical bone model
Corrective osteotomies / Guides and plates based on the calculated deformity angles.

Corrective osteotomies

Guides and plates based on the calculated deformity angles.

Patient-specific plate on a long bone model
Anatomy-matched plates / Contour and holes — matched to the specific bone.

Anatomy-matched plates

Contour and holes — matched to the specific bone.

Acetabular component on an anatomical model with supports
Anatomical models / Trial fitting of the component and fixation planning before surgery.

Anatomical models

Trial fitting of the component and fixation planning before surgery.

Materials

Material chosen for the task

MaterialPropertiesWhere it is used
Medical-grade Ti-6Al-4V titaniumStrength; porous SLM structures for bone contactCups, augments, fixation devices, defect reconstruction
Ultra-high-molecular-weight polyethylene (UHMWPE)Material for articulating bearing surfacesArticular surfaces, liners
Medical-grade PEEKLight weight, biocompatibility, radiolucency (CT/MRI follow-up)Individual components according to the clinical task
Biocompatible photopolymerMaterial for guides and trial-fit modelsResection and drilling guides

The choice of material is determined by the clinical task and the physician's decision. This summary is general in nature.

How the process works

From CT to the kit in the operating room

1

CT and the clinical task

MSCT per protocol, description of the defect and the plan.

2

3D model and plan

Segmentation, calculation of axes, correction volume and screw channels.

3

Approval with the surgeon

Geometry, access and fixation points — before manufacturing.

4

Manufacturing and delivery

Implant, guides and models — delivered to the clinic.

Patient-specific acetabular components
Patient-specific acetabular components — Ti-6Al-4V titanium
Limitations

What to keep in mind

  • Planning accuracy depends on the quality of the CT and on following the protocol correctly
  • With pronounced metal artefacts, repeat imaging may be required
  • The approach, access and extent of correction are determined by the surgical team
  • A patient-specific device does not replace clinical judgement and does not guarantee an outcome
What you receive

Kit

  • A patient-specific implant or fixation device
  • Surgical guides (if required)
  • Anatomical model for trial fitting
  • Supporting materials for the project
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

Patient-specific acetabular cups and augments, sets of guides and fixation plates for corrective osteotomy, implants for knee revision surgery and long bone defect reconstruction, and components for articular surface replacement.

Fixation hardware is calculated during 3D modelling: screws are placed in zones of higher bone density, the surgical access is worked out in advance, and the shape and angle of fixation are adapted to the defect.

Porous titanium zones at the bone interface are intended for bone contact and ingrowth. This is a design feature; the clinical outcome depends on the situation and is determined by the physician.

MSCT per protocol with full coverage of the anatomical segment, primary axial DICOM series. Details are in the CT protocols section.

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. Custom designed and 3D-printed titanium pelvic implants for acetabular reconstruction after tumour resection. [source]
  2. Custom 3D-printed implants for acetabular reconstruction: intermediate-term functional and radiographic results. JBJS Open Access. 2023. [source]
  3. Custom 3D-printed porous titanium augments for Paprosky type III acetabular defects. 3D Print Med. 2025. [source]
  4. Kurtz SM, Devine JN. PEEK biomaterials in trauma, orthopedic, and spinal implants. Biomaterials. 2007;28(32):4845–4869. [source]
Related solutions

What else you may need

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
  • design a patient-specific construct for the specific defect
  • prepare guides for the corrective osteotomy
  • manufacture an anatomical model
  • agree the geometry and fixation with the surgeon
What we cannot determine without the physician and the source data
  • the medical indications for surgery
  • surgical access
  • soft tissue condition
  • the prognosis of the clinical outcome
  • choice of surgical approach
  • whether a particular material is acceptable

A complex defect or a revision?

Send us a CT — an engineer will assess applicability and propose a construct with a fixation plan.

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.