Abstract: In this study, in order to prevent the failure of hemipelvic arthroplasty using a patient-specific Computer-Aided Design (CAD) and Additive Manufacturing (AM) approach, a new design for modular hemipelvic prosthesis was developed. Moreover, the biomechanical properties of the new design were determined. The 3D printed pelvic prosthesis with a sacrum portion that completely matches the back surface of the patient’s sacrum offers more potential for bone ingrowth between the host bone and prosthesis. The new approach integrated the capabilities of digital medical imaging techniques, CAD and metal AM to realize a modular hemipelvic prosthesis. The patient’s pelvic Digital Imaging and Communication in Medicine (DICOM) data were imported into Mimics software to construct a digital representative patient model for design of the prosthesis. A physical model was obtained using a Stereolithography (SLA) 3D printer for preoperative planning. The final customized implant was designed by using UG NX 10.0 software. Then a surgically modular hemipelvic prosthesis was fabricated from the Ti6Al4V titanium alloy by electron beam melting technology. The operation was performed according to the preoperative planning. The outcome of the operation was good at the 6-month follow-up. Also, the stress distribution and the relative micromotion revealed positive results based on a finite element model built to detect prosthesis stability. The 3D printed modular hemipelvic prosthesis provided good resolution for the failure of hemipelvic arthroplasty. Personal customization will be important in future surgeries aiming at improving the anatomy and function of the implant.

Key words: 3D printing, hemipelvic prosthesis, 3D reconstruction, rapid prototype, bionic, prosthesis design