OsteoFab® PEKK: Custom, Metal-Free Implants
- Kelly Williams
- Nov 6
- 4 min read
Complex skeletal defects of the skull, face and extremities challenge even the most experienced reconstructive surgeons. Traditional titanium plates and meshes can restore form, yet they introduce limitations. Metallic implants may cause imaging artefacts, interfere with radiotherapy planning and can become sources of infection or thermal sensitivity. OsteoFab® patient-specific implants manufactured from PEKK polymer offer a completely custom solution that overcomes these drawbacks.
The Science of PEKK
Polyetherketoneketone (PEKK) is a high-performance thermoplastic with exceptional mechanical strength and chemical resistance. Its elasticity modulus closely approximates that of cortical bone, which improves load sharing and reduces stress shielding. PEKK is naturally radiolucent, enabling postoperative CT and MRI imaging free of streak artefacts. The material is inert, biocompatible, and has a proven track record in medical-device applications, with excellent resistance to infection and thermal conductivity comparable to native bone.
For the surgeon, this means a material that behaves more like bone than metal while maintaining the structural reliability essential for demanding reconstructions.
Workflow: From Scan to Implant
Every OsteoFab® implant begins with high-resolution patient imaging. CT data are converted into a full 3D model accurately representing the defect and adjacent anatomy. Using advanced CAD software, engineers collaborate with the surgeon to design a restoration that both looks and functions as intended. Virtual surgical planning sessions ensure alignment with surgical goals before manufacturing begins. This digital workflow eliminates intraoperative guesswork and delivers an implant that fits correctly first time.
Additive Manufacturing: Precision Layer by Layer
OsteoFab® implants are produced using laser-sintered additive manufacturing of PEKK polymer. This layer-by-layer technique allows the creation of complex geometries, fine surface details and patient-specific contours that traditional machining cannot achieve. The process is tightly controlled for dimensional accuracy and mechanical integrity. Once printed, each implant undergoes rigorous finishing, cleaning and sterilisation in line with regulatory standards. Surgeons receive implants that exactly match the approved digital model to sub-millimetre precision.
Surgical Technique: Familiar Fixation, Enhanced Handling
Implantation of an OsteoFab® device follows standard reconstructive principles. After defect exposure and recipient bone preparation, the custom PEKK implant is placed using pre-planned orientation markers. Because the material is lightweight and readily drillable, surgeons may use standard titanium screws for fixation without risk of material splintering or cracking. The radiolucent nature of the implant permits immediate intraoperative imaging to verify alignment without artefact—offering confidence prior to closure.
Clinical Outcomes: Proven Reliability
Multicentre studies and case reports show excellent outcomes in cranio-maxillofacial reconstruction, limb salvage and complex orthopaedic oncology. Surgeons report high levels of patient satisfaction with contour restoration and long-term stability. Follow-up imaging confirms retention of shape and integration with surrounding tissues, while the absence of metallic artefacts enables accurate postoperative assessment and facilitates future radiotherapy planning. Reported complication rates are low and comparable to or better than those associated with metallic reconstructions.
Key Advantages for Surgeons and Patients
True patient-specific design for an exact anatomical fit
Radiolucent material allowing clear CT and MRI imaging
Mechanical properties closely matched to cortical bone for natural load sharing
Excellent biocompatibility and low infection risk
No need for removal or concern about thermal sensitivity
Together these attributes reduce surgical time, simplify postoperative management and improve both functional and cosmetic outcomes.
Broad Applications: From Craniofacial to Extremity Reconstruction
OsteoFab® implants span a wide range of applications. In cranio-maxillofacial surgery they restore large skull defects following trauma or tumour resection. For limb reconstruction they replace bone segments lost to infection or malignancy. Integrated fixation points and porous regions for soft-tissue ingrowth make them suitable for demanding orthopaedic cases where conventional hardware would be bulky or difficult to contour.
Operational Efficiency: Economic and Practical Benefits
Although each implant is custom-made, the digital workflow streamlines production and reduces operative time. The elimination of intraoperative contouring and the predictable fit can shorten theatre sessions and lower overall cost of care. Radiolucency eliminates the need for specialised imaging protocols, saving time during follow-up and allowing precise monitoring of adjacent tissues. Avoiding the need for future hardware removal further reduces long-term expense.
Patient Impact: Better Outcomes
Patients benefit from a lightweight implant that mirrors their anatomy. They avoid the cold-sensitivity sometimes associated with metal plates and enjoy a natural appearance and minimal contour irregularity. Surgeons value the ease of placement, the freedom to image without artefact and the ability to plan future procedures without retained metal constraints.
Conclusion: Custom Reconstruction Without Compromise
OsteoFab® PEKK implants bring together cutting-edge imaging, precise engineering and a biologically-friendly material to deliver custom, metal-free reconstructions. For surgeons seeking accuracy, strength and long-term stability without the limitations of titanium, PEKK represents the next-generation solution. From the first CT scan to final surgical outcome, OsteoFab® technology places patient-specific design at the heart of modern reconstructive surgery.
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