Personalized cranial implants: pioneering techniques with additive manufacturing

Abstract

The development of cranial implants has progressed from traditional autologous bone grafts and manually shaped implants to computer-aided design and manufacturing (CAD/CAM) and, more recently, additive manufacturing (AM). AM enables the production of patient-specific cranial implants with complex geometries and enhanced precision. This chapter examines the evolution of cranial implant manufacturing, emphasizing the advantages of AM over traditional methods and its positive impact on clinical outcomes. It also explores point-of-care (POC) manufacturing, where hospitals can design and produce implants onsite, enhancing accessibility and efficiency. Through clinical scenarios, the chapter highlights various customization strategies, including hybrid and fully AM-based implants for cranial reconstructions. Finally, it addresses key challenges such as regulatory compliance and discusses future trends, including Artificial Intelligence (AI)-driven design, real-time quality control, and multi-material printing, establishing AM as a transformative technology for personalized cranial reconstruction.