Israeli Surgeons 3D-Print New Chest Cage After Rare Tumor Surgery

A Rare Tumor, a Complex Decision

A young woman in her twenties arrived at Clalit-Beilinson Hospital in Petah Tikva with a tumor eroding her sternum. What looked like a benign cartilage growth turned out to be a BRAF-altered mesenchymal tumor, a sarcoma so rare that only about 20 cases have been reported worldwide. The standard reconstruction options, synthetic mesh, titanium plates, or bone cement, would not give her the flexibility needed to breathe and move normally.

Why PEKK and 3D Printing

The surgical team chose a fully customized implant made from PEKK, polyetherketoneketone. This high-performance polymer combines the strength of carbon fiber-reinforced materials with the flexibility of living bone. Dr. Israel Weiss, Head of Orthopedic Oncology, said that flexibility matters for a body part that moves with every breath. The material also lets surrounding tissue grow into the implant over time.

Using the patient's CT scans, the team built a digital twin of her healthy chest. They recreated the loads the sternum bears during walking, breathing, and movement. That data determined the exact internal network of the implant, point by point. Fixation screws were placed where bone quality was strongest. The entire plan was rehearsed with a printed model before surgery.

The Operation and Recovery

The operation lasted about two hours. Surgeons removed the diseased sternum and portions of several ribs, then fitted the custom implant through an incision beneath the breasts to minimize scarring. The patient was discharged after several days and is recovering at home.

Dr. Yury Peysakhovich, Head of Thoracic Surgery, described the sternum as the anchor of the entire chest. If reconstruction is not precise, both breathing mechanics and heart and lung protection can be compromised. Every breath, cough, or physical movement places significant stress on that area.

What Comes Next

The medical team has already performed two more procedures using the same technology. They want to build a standard protocol that lets them treat a larger volume of patients. Rare cases require creative solutions, Peysakhovich said. The combination of advanced 3D printing and close collaboration across surgical specialties offered this patient something that simply was not available a few years ago.