This was an 8 month long academic research project for my third year of university. It was proposed by an academic supervisor in conjunction with a paediatric orthopaedic surgeon. This project aimed to analyse how the NHS performs osteotomies, and determine whether incorporating 3D printed surgical jigs would improve the patient experience and reduce the failure rate of these surgeries, as well as determine if incorporating 3D printed jig manufacture in the NHS is viable. This was all done with an engineering method to determine the best approach to manufacture and incorporate custom 3D printed jigs into surgeries within the NHS.

First the status quo for osteotomies in the NHS was analysed to provide a baseline process for the project which could be amended to clearly state how 3D printed jigs could be introduced. Then the methodology for introducing 3D printed jigs into the NHS’s osteotomy process was determined whereby the operating surgeon would use medical imaging and specialist 3D planning software to design the jig before it could be 3D printed.

This project took the assumption that jigs would be manufactured by FDM 3D printing as it is low cost and has a shallow learning curve for hospital staff. Extensive material analysis was performed to determine the optimal material for 3D printed jigs; taking into account the manufacturing process, the use case, the short useful lifespan, and sustainability goals, high impact PLA was deemed the most suitable material. 

The print setting variables in 3D printing were determined for 3D printed jigs in this particular use case made from high impact PLA, where expected forces were analysed, and testing concluded the optimal infill value and pattern to ensure the jigs were strong enough to survive intended use, with redundancy, to be 25% infill with a hexagonal infill pattern. 

A final proposal for amendments to the status quo NHS process for osteotomies was detailed, concluding that introducing 3D printed jigs is likely suitable for osteotomies in the NHS and could reduce post-surgery complications that require additional surgery by over 40%. Post-proposal, limitations of this paper, its research and results, were provided with the aim of ensuring the proposal goes through additional rigorous testing to ensure full safety and feasibility in a medical setting.

This project was a success, and it was determined that it is likely that the introduction of 3D printed jigs to the NHS would improve patient satisfaction, reduce waiting times, reduce surgery failures, and reduce the environmental impact for any procedures where custom jigs were already necessary. However a lot more testing and research would be needed before this can be implemented in the NHS. Should you wish to learn more about this project, or read my final report, please contact me.