3D Printing for Patient-Specific Surgical Planning and Rehabilitation

How personalised tools can enhance precision, anatomy and recovery

3D printing in my practice is not a marketing add-on or a cosmetic “simulation.” It is a clinical instrument used selectively when it genuinely improves planning, accuracy or patient comfort.

I use 3D printing because it supports surgical thinking, not because it sounds modern.

1. Where It Began - Early Work with Patient-Specific PEEK Implants

My interest in personalised surgical tools started early with CAD/CAM PEEK implants for cranioplasty. This work became one of the most cited publications in the field and introduced me to:

personalised implant design
skull reconstruction biomechanics
the advantages of patient-specific implants over generic alternatives

Even at that stage, I wondered if PEEK could eventually be 3D-printed on demand, allowing same-day cranial reconstruction. Years later, I would see this become reality in Switzerland.

2. Low-Cost Surgical Innovation - 3D-Printed Microsurgery Training Tools

Later, while collaborating with a colleague supporting microsurgical training in Ethiopia, we needed a high-fidelity, low-cost way to teach microvascular anastomosis without a microscope. We developed a practical solution using:

a smartphone as the “microscope”, and
3D-printed microvascular clamps designed to simulate real instrumentation

This project:

reduced barriers to microsurgery training
created a reproducible, inexpensive teaching model
received international recognition through a featured publication and a Best Abstract Award
reinforced my belief that innovation should be useful, not decorative

ISEM Best Abstract Award Certificate.jpg

3. Switzerland - Integrating 3D Planning into Real Clinical Cases

During my time in Switzerland, 3D printing became part of everyday clinical work. I routinely used:

Patient-specific cutting guides for hand & wrist corrective osteotomies - these guides allow precise bone re-alignment in post-traumatic malunions
Anatomical 3D models for reconstructive planning - helpful for complex trauma, congenital differences and multi-planar deformities
Custom orthoses for rehabilitation - lightweight, personalised supports that improve comfort and function

A defining moment was being invited to visit an in-house 3D printing unit at the University Hospital of Basel, where they were producing same-day 3D-printed PEEK cranial implants - essentially realising the concept I first imagined more than 10 years ago.

4. Singapore - Focused, Practical Use of 3D Printing Today

In Singapore, my use of 3D printing remains selective and purpose-driven - never for marketing, always for measurable benefit.

4.1 Corrective Osteotomies (Hand & Wrist)

For complex deformities after fractures, I use 3D printing to:

analyse deformity in three dimensions
plan corrective cuts virtually
produce patient-specific cutting guides
improve alignment accuracy during surgery

Benefits for patients include:

improved functional biomechanics
potentially shorter operative times
more predictable results
better long-term comfort

4.2 Microsurgery Training & Education

While not part of routine clinical care, my work with 3D-printed microvascular clamps continues to shape my approach to:

microsurgery precision
teaching methodology
global surgical accessibility

This reflects a consistent philosophy: technology should make good surgery easier to teach, not harder to access.

4.3 Personalised Upper Limb Casts & Orthoses

Through my collaboration with industry, I assess patients who may benefit from transitioning into 3D-printed:

casts
splints
orthoses

These offer advantages such as:

lighter weight
greater ventilation
better hygiene in humid climates
anatomical fit and improved comfort

Again - not a novelty, but a clinically sensible alternative for selected patients, especially in Singapore's weather.

5. My Approach to 3D Surgical Tools

The principles that guide my use of 3D printing are simple:

Anatomy comes first - technology must follow anatomy, not override it
Selective use - only applied when it clearly benefits diagnosis, precision or comfort
No gimmicks - I do not use “3D imaging of cosmetic surgery results” as these are but enhanced photographs, not surgical planning tools
Practical and safe - every printed guide or orthosis must make anatomical, biomechanical and clinical sense
Precision with purpose - 3D printing is applied only when it meaningfully improves clarity or outcome

6. Who This Is Suitable For

3D-assisted surgical planning or 3D-printed devices may help if you have:

complex hand/wrist deformities
a malunion requiring corrective osteotomy
a need for improved cast comfort
difficulty tolerating traditional splints
interest in personalised rehabilitation devices
a case where added precision improves predictability

Patients who are considering switching to a lighter, better-fitting 3D-printed splint may request an assessment. I can advise whether it is suitable and guide the process if indicated, through my existing 3D-printing partners.

7. A Simple Philosophy

"Use technology where it elevates precision and patient experience. Use anatomy everywhere."

For me, 3D printing is not a buzzword. It is another way to deliver thoughtful, personalised surgical care.

Frequently Asked Questions

1. What types of surgery benefit most from 3D printing?
3D printing is particularly helpful in complex hand and wrist corrective osteotomies, especially post-traumatic malunions. It allows precise analysis, planning and production of cutting guides that improve alignment and biomechanical outcomes.

2. How do 3D-printed patient-specific guides improve surgery?
By translating a virtual surgical plan into a physical guide, 3D printing enhances intra-operative precision, potentially shortens operative time and improves predictability, especially where three-dimensional deformities exist.

3. Does 3D printing replace clinical judgement?
No. Technology is a tool that supports clinical decision-making. Anatomy, functional goals and surgical judgement remain the foundation. 3D printing is only applied when it clearly benefits diagnosis, precision or comfort.

4. Are 3D-printed orthoses custom-fitted?
Yes, when indicated, custom 3D-printed casts, splints and orthoses offer lighter weight, improved ventilation, better hygiene and a more anatomical fit compared with traditional splinting, particularly useful in Singapore’s humid climate.

5. Is 3D printing used for cosmetic simulation or marketing?
No, in this practice it is never used for cosmetic simulation or marketing purposes. The focus is on clinically meaningful applications that support surgical planning, training and functional rehabilitation.