Layerwise Builds The World’s First Patient‐Specific Lower Jaw Using Laser Technology

LayerWise applied Additive Manufacturing (AM) to produce an award winning Titanium lower jaw reconstruction. The implant is developed in collaboration with project partners in medical industries and academia. To treat a senior patient's progressive osteomyelitis of almost the entire lower jaw bone, surgeons opted for such a complete patient-specific implant the first time ever. 

Credit: LayerWise applied Additive Manufacturing

AM technology specialists at LayerWise printed the complex implant design incorporating articulated joints and dedicated features. The reconstruction - post-processed with dental suprastructure provisions, polished joint surfaces and a bioceramic coating - has been implanted successfully. It restored the patient's facial esthetics and allowed her to regain her speach within hours.  

“Besides a successful track record in industrial sectors, metal AM is gaining importance in medical implantology. AM’s freedom of shape allows the most complex freeform geometries to be produced as a single part prior to surgery. As illustrated by the lower jaw reconstruction, patient-specific implants can potentially be applied on a much wider scale than transplantation of human bone structures and soft tissues. The use of such implants yield excellent form and function, speeds up surgery and patient recovery, and reduces the risk for medical complications.”

A giant leap forward in mandibular treatment

Dr. ir. Peter Mercelis, Managing Director of LayerWise: “Besides a successful track record in industrial

sectors, metal AM is gaining importance in medical implantology. AM’s freedom of shape allows the most complex freeform geometries to be produced as a single part prior to surgery. As illustrated by the lower jaw reconstruction, patient‐specific implants can potentially be applied on a much wider scale than transplantation of human bone structures and soft tissues. The use of such implants yield excellent form and function, speeds up surgery and patient recovery, and reduces the risk for medical complications.”

The world’s first patient‐specific total lower jaw implant, produced by AM specialist LayerWise.

Credit: LayerWise

Prof. Dr. Jules Poukens of the University Hasselt: “The new treatment method is a world premiere because it concerns the first patient‐specific implant in replacement of the entire lower jaw. The implant integrates multiple functions, including dimples increasing the surface area, cavities promoting muscle attachment, and sleeves to lead mandible nerves. Furthermore, the mandible implant is equipped to directly insert dental bar and/or bridge implant suprastructures at a later stage. I led the team of surgeons who implanted the AM‐produced structure during a surgery of less than four hours at the Orbis Medisch Centrum in Sittard‐Geleen. Shortly after waking up from the anesthetics the patient spoke a few words, and the day after the patient was able to speak and swallow normally again.”

Surgeons replaced the entire lower jaw bone structure with  a patient‐specific total mandible implant

Credit: LayerWise

The new method has been developed by the Biomed research group of the University Hasselt (B) in

collaboration with engineers from the Xios Hogeschool (B), Xilloc Medical BV (NL) and University

Leuven and maxillofacial surgeons from the Orbis Medisch Centrum Sittard‐Geleen (NL). LayerWise

NV (B) produced the implant structure, which was coated with a bioceramic coating by Cam Bioceramics BV (NL).

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