Costa Rica Implants First 3D-Printed Cranial Prosthesis

Costa Rica's public health system has completed its first cranioplasty using a fully in-house 3D-printed cranial prosthesis. The surgery, performed at San Juan de Dios Hospital, marks a milestone for the Caja Costarricense de Seguro Social, which spent roughly two years building the workflow from CT scan to sterilization.

The patient-specific prosthesis was made from PEEK, a high-performance thermoplastic that is lightweight, radiolucent, and chemically stable. Unlike metal plates, PEEK does not distort MRI or CT images, which matters for follow-up care. The Caja says it invested about 115 million colones, roughly $252,000, in printers, curing equipment, software, and materials. Producing a small prosthesis internally costs around $2,554, which the institution says cuts expenses by up to 64% compared with outsourcing.

The manufacturing path is straightforward but precise. CT or MRI scans are segmented in software, the healthy side of the skull is mirrored to reconstruct the defect, and the surgeon reviews the design before printing. After fabrication, the piece is sanded, polished, cleaned, packaged, and sterilized. From imaging to implantation, the process takes about seven days.

By mid-2026, the Caja expects 52 patients across three hospitals to benefit from the new capability. The program is not limited to cranial prostheses. The same team has produced surgical planning guides, anatomical models, pill organizers, umbilical cord clamps, and industrial spare parts.

The cost and speed gains are significant, but the real win is local control. When a hospital can manufacture its own implants, it removes dependency on international suppliers, shipping delays, and outside pricing. For a public system serving a mixed-income population, that independence translates directly into access.