Surgical technique: sternal reconstruction using a three-dimensional printed polyetherketoneketone prosthesis
Year: 2026
Type: article
Study design: Case Report
Abstract: Sternal resection is occasionally required for the treatment of primary or secondary malignancies. Subsequent sternal reconstruction is necessary to preserve chest wall integrity and respiratory mechanics while protecting underlying vital organs; however, it remains a significant challenge. Various methods and materials have been described for sternal reconstruction, yet all have limitations and there is no consensus on the optimal reconstructive strategy. In general, rigid materials provide better protection of underlying organs, however, they have a propensity to poorly integrate into surrounding tissues and therefore are susceptible to infection or dislodgement. More pliable materials typically have better potential to integrate into surrounding tissues, however, they may not provide optimal chest wall mechanics or protection with poor aesthetic outcomes. Three-dimensional (3D) printing technology has recently been developed which provides individualized human prosthetic bone reconstruction. Polyetheretherketone (PEEK) is a high-performance thermoplastic polymer known for exceptional strength and very amenable to 3D-printing. Accordingly, PEEK prostheses are now utilized for spine and other orthopedic reconstructions. In vivo studies have demonstrated polyetherketoneketone (PEKK), a member of the polyaryletherketone (PAEK) family, has excellent osseointegration and antibacterial properties, as compared to other members of PAEK family. In this regard, 3D printed PEKK sternal prostheses could potentially have advantages of providing individualized conformed rigidity to the chest wall while promoting surrounding bone ingrowth. In this report, we describe the technical aspects of successful sternal reconstruction using a 3D-printed PEKK prosthesis after subtotal sternectomy for an invasive mediastinal germ cell tumor.
Authors: Rachit Gupta, Andrea West, Kenneth A. Kesler
Institution: Community Health Network
Language: English
Subfield: Biomedical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: diamond
OpenAlex ID: W7204267011