Personalized 3D-printed implant for thoracic vertebra body replacement after the total en bloc resection of a tumor with two-year follow up period

Abstract Background This monocenter prospective study assessed the efficacy of 3D-printed personalized vertebral implants in reconstructing spinal stability following total en bloc spondylectomy (TES) for benign spinal tumors. Given the absence of specialized implants for post-resection reconstruction, this approach integrates 3D-printed implants for anatomical precision, stability, and improved postoperative outcomes. Methods Four patients who underwent TES and received customized 3D-printed vertebral implants were included. Data on surgical duration, blood loss, pain (VAS), and disability (ODI) were collected. Mechanical testing assessed implant durability, and follow-up evaluations were conducted over two years to monitor functional and neurological outcomes. Results The personalized implants demonstrated mechanical stability with no deformations at high loads. Post-surgical VAS and ODI scores showed significant improvements, reflecting reduced pain and enhanced functional outcomes. Neurological assessments indicated 75% of patients achieved full function recovery. CT imaging confirmed stable implant positioning, with no fixation failures or complications. Conclusions This study highlights the potential of 3D-printed implants for personalized spinal reconstruction, enhancing surgical planning and reducing procedure time and blood loss. Though promising, further research with larger cohorts is needed to establish long-term efficacy in various clinical settings.