Israeli Surgeons Replace Chest Wall With 3D-Printed PEKK Rib Cage

Surgeons at Israel's Beilinson Hospital have completed a chest wall reconstruction using a custom 3D-printed implant made from PEKK, or polyetherketoneketone. The procedure replaced part of the sternum and adjacent ribs in a young patient, marking another step for additive manufacturing in complex orthopedic reconstruction.

Why PEKK

PEKK is a high-performance thermoplastic used increasingly in medical implants. It is radiolucent, meaning it does not interfere with CT or MRI imaging. It also has a modulus of elasticity closer to bone than metal, which can reduce stress shielding. Those properties make it attractive for craniofacial and thoracic reconstruction where long-term imaging follow-up matters.

The Procedure

The team at Beilinson Hospital, part of the Rabin Medical Center, designed the implant to match the patient's anatomy. 3D printing allowed them to replicate the complex geometry of the rib cage and sternum in a single piece. The approach avoids some of the complications associated with harvesting autologous bone or shaping metal implants to fit irregular defects.

Context

3D-printed chest wall reconstructions are still relatively uncommon, but the clinical case count is growing. Earlier cases have used titanium and, more recently, PEEK. PEKK sits in the same family as PEEK but processes at slightly different temperatures and can offer better interlayer adhesion in certain geometries. Oxford Performance Materials has been one of the main commercial drivers of PEKK for medical devices.

This case matters because chest wall reconstruction after tumor resection or trauma is one of the harder problems in orthopedic surgery. The rib cage moves with every breath, so the implant must be strong, lightweight, and stable enough to tolerate repeated loading. A custom printed fit reduces the need for intraoperative bending or grafting.