Personalization and Precision: Innovative Applications and Future Challenges of Additive Manufacturing in Orthopedic Implants

Abstract

<p>When significant structural defects (such as post tumor removal or severe bone defect) exceed the body's inherent capacity for self-repair, orthopedic implants remain an effective clinical option for restoring skeletal structural integrity and mechanical function. Conventional subtractive manufacturing, however, often lacks the precision, customization, and structural complexity demanded by modern implant design. Additive manufacturing (AM) has emerged as a transformative alternative, enabling layer-by-layer fabrication tailored to patient-specific anatomy. This review explains the underlying principles of AM and its application to orthopedic implant design, highlighting how the technology surpasses traditional machining in accuracy, design freedom, and personalization. We outline end-to-end workflow that couples computer-aided design with detailed patient-specific anatomical data to produce bespoke implants, and we compare major AM modalities—powder bed fusion, material extrusion, directed energy deposition, and stereolithography—focusing on their strengths, limitations, and clinical suitability. Recent clinical deployments and research advances are surveyed to illustrate the positive impact of AM on postoperative recovery, implant longevity, and patient comfort. Finally, we discuss the challenges of scaling AM for mass production and consider future directions, emphasizing opportunities for interdisciplinary collaboration that could broaden the technology's reach in personalized orthopedic care.</p>