Comparative study of 3D printed navigation template-assisted atlantoaxial pedicle screws versus free-hand screws for type II odontoid fractures

Comparison of Safety and Perioperative Outcomes Between Patient-specific Template-Guided and Fluoroscopic-Assisted Freehand Lumbar Screw Placement Using Cortical Bone Trajectory Technique

STUDY DESIGN

Non-randomized prospective controlled study.

OBJECTIVES

To compare the safety and perioperative outcomes between patient-specific template-guided and fluoroscopic-assisted freehand techniques in transforaminal lumbar interbody fusion (TLIF) using cortical bone trajectory (CBT).

METHODS

The subjects consisted of 94 consecutive patients who underwent single-level TLIF using CBT. The standard trajectory was set so as to start from the pars interarticularis, pass the inferior border of the pedicle, and end around the middle of the vertebral endplate. Template guide technique was performed in 66 patients (Guide group), and fluoroscopic-assisted freehand technique was performed in 28 patients (Freehand group). Intraoperative parameters, screw placement accuracy, and complications were compared between the two techniques.

RESULTS

The Guide group had significantly shorter operative and radiation exposure times than the Freehand group (operative time 84.6 ± 16.7 vs 93.0 ± 15.0 minutes; P = .023, radiation exposure time 7.0 ± 6.0 vs 20.4 ± 11.8 seconds; P < .001, respectively). The screw diameter and the screw insertion depth in the vertebra in the Guide group were significantly greater than those in the Freehand group. The degree and incidence of facet joint violation were comparable between the two groups, while the accuracy of screw placement was significantly different, with no perforation rate of 97.7% in the Guide group vs 82.1% in the Freehand group (P < .001). No significant difference was found in the rate of clinically relevant complications between the two groups.

CONCLUSIONS

The template-guided technique provided a safe and highly accurate option for CBT screw placement.

Systematic review of the utility and limits of 3D printing in spine surgery

OBJECTIVE

The main objective of this study has been to demonstrate why additive printing allows to make complex surgical pathological processes that affect the spine more visible and understandable, increasing precision, safety and reliability of the surgical procedure.

METHODS

A systematic review of the articles published in the last 10 years on 3D printing-assisted spinal surgery was carried out, in accordance with PRISMA 2020 declaration. Keywords "3D printing" and "spine surgery" were searched in Pubmed, Embase, Cochrane Database of Systematic Reviews, Google Scholar and Opengrey databases, which was completed with a manual search through the list of bibliographic references of the articles that were selected following the defined inclusion and exclusion criteria.

RESULTS

From the analysis of the 38 selected studies, it results that 3D printing is useful in surgical planning, medical teaching, doctor-patient relationship, design of navigation templates and spinal implants, and research, optimizing the surgical process by focusing on the patient, offering magnificent support during the surgical procedure.

CONCLUSIONS

The use of three-dimensional printing biomodels allows: making complex surgical pathological processes that affect the spine more visible and understandable; increase the accuracy, precision and safety of the surgical procedure, and open up the possibility of implementing personalized treatments, mainly in tumor surgery.

The Role of 3D Printing in Treatment Planning of Spine and Sacral Tumors

Three-dimensional (3D) printing technology has proven to have many advantages in spine and sacrum surgery. 3D printing allows the manufacturing of life-size patient-specific anatomic and pathologic models to improve preoperative understanding of patient anatomy and pathology. Additionally, virtual surgical planning using medical computer-aided design software has enabled surgeons to create patient-specific surgical plans and simulate procedures in a virtual environment. This has resulted in reduced operative times, decreased complications, and improved patient outcomes. Combined with new surgical techniques, 3D-printed custom medical devices and instruments using titanium and biocompatible resins and polyamides have allowed innovative reconstructions.

Individualized 3D-printed navigation template-assisted tension band wiring for olecranon fractures

PURPOSE

3D printing techniques guide precision medicine and show great development potential in clinical applications. The purpose of this study was to compare the clinical outcomes of 3D-printed navigation templates versus free-hand in tension band wiring (TBW) procedures for olecranon fractures.

METHODS

Patients who underwent TBW due to Mayo type II olecranon fractures between January 2019 and December 2021 in our hospital were prospectively enrolled in the study. The patients were divided into the 3D printed navigation template guiding TBW group (3D printed group) and the free-hand TBW group (free-hand group). The primary endpoint of this study was the success rate of the bicortical placement of Kirschner wires (K-wires). Times of intraoperative fluoroscopy, operation times, complications, VAS scores, and Mayo Elbow Performance Scores (MEPS) were analyzed as the secondary outcomes measure.

RESULTS

The success rate of the bicortical placement of K-wires was 85.7% in the 3D Printed group was significantly higher than the free-hand group (60%). There were fewer times of intraoperative fluoroscopy in the 3D Printed group (1.43 ± 0.51) than that in the free-hand group (2.60 ± 1.00) with statistical significance (P < 0.05). At the date of the last follow-up, four patients suffer from pain and skin injury at the K-wires insertion site in the 3D Printed group and 14 patients in the free-hand group, a significant difference between the two groups (P < 0.05). No statistically significant differences were found in operation time, VAS scores, and MEPS between the two groups.

CONCLUSIONS

The individualized 3D-printed navigation template-assisted TBW demonstrated good accuracy and resulted in reduced times of intraoperative fluoroscopy and complication compared to the free-hand TBW for olecranon fractures.

Biomechanical comparative study of midline cortical vs. traditional pedicle screw trajectory in osteoporotic bone

INTRODUCTION

In lumbar spinal stabilization pedicle screws are used as standard. However, especially in osteoporosis, screw anchorage is a problem. Cortical bone trajectory (CBT) is an alternative technique designed to increase stability without the use of cement. In this regard, comparative studies showed biomechanical superiority of the MC (midline cortical bone trajectory) technique with longer cortical progression over the CBT technique. The aim of this biomechanical study was to comparatively investigate the MC technique against the not cemented pedicle screws (TT) in terms of their pullout forces and anchorage properties during sagittal cyclic loading according to the ASTM F1717 test.

METHODS

Five cadavers (L1 to L5), whose mean age was 83.3 ± 9.9 years and mean T Score of -3.92 ± 0.38, were dissected and the vertebral bodies embedded in polyurethane casting resin. Then, one screw was randomly inserted into each vertebra using a template according to the MC technique and a second one was inserted by freehand technique with traditional trajectory (TT). The screws were quasi-static extracted from vertebrae L1 and L3, while for L2, L4 and L5 they were first tested dynamically according to ASTM standard F1717 (10,000 cycles at 1 Hz between 10 and 110 N) and then quasi-static extracted. In order to determine possible screw loosening, there movements were recorded during the dynamic tests using an optical measurement system.

RESULTS

The pull-out tests show a higher pull-out strength for the MC technique of 555.4 ± 237.0 N compared to the TT technique 448.8 ± 303.2 N. During the dynamic tests (L2, L4, L5), 8 out of the 15 TT screws became loose before completing 10,000 cycles. In contrast, all 15 MC screws did not exceed the termination criterion and were thus able to complete the full test procedure. For the runners, the optical measurement showed greater relative movement of the TT variant compared to the MC variant. The pull-out tests also revealed that the MC variant had a higher pull-out strength, measuring at766.7 ± 385.4 N, while the TT variant measured 637.4 ± 435.6 N.

CONCLUSION

The highest pullout forces were achieved by the MC technique. The main difference between the techniques was observed in the dynamic measurements, where the MC technique exhibited superior primary stability compared to the conventional technique in terms of primary stability. Overall, the MC technique in combination with template-guided insertion represents the best alternative for anchoring screws in osteoporotic bone without cement.

C2 pedicle screw placement on 3D-printed models for the performance assessment of CTA-based screw preclusion

BACKGROUND

3-D printing technology has a large spectrum of applications in upper cervical spinal surgery, but none have evaluated the radiological analysis of the feasibility of C2 pedicle screw placement. Thus, this study aimed to perform 3.5-mm-diameter C2 pedicle screw placement on models for performance assessment of CTA-based preoperative screw preclusion.

METHODS

We enrolled 152 patients who underwent CTA of the cervical spine between April 2020 and December 2020. Transverse pediculoisthmic width (TPW), oblique pediculoisthmic width (OPW), minimum pediculoisthmic diameter (MPD), internal height, and isthmus height were measured preoperatively. Subsequently, 1:1 3D-printed bone models were created, and a 3.5-mm-diameter C2 pedicle screw was placed on the models. All 3D-printed models underwent postoperative CT multiplanar reconstruction to evaluate the screw trajectory for the performance assessment of CTA-based preoperative screw preclusion.

RESULTS

The ROC curves of the MPD, TPW, OPW, Internal height and Isthmus height showed that the optimal cutoff values for each of the five groups were measured values of 4.78, 4.44, 4.37, 4.22 and 5.59 mm, respectively. The AUC, sensitivity, and specificity of MPD were 0.992, 95.1% and 100%, respectively. The MPD had higher metrics than the TPW (AUC, 0.949; sensitivity, 87.9%), internal height (AUC, 0.885; sensitivity, 80.8%; specificity, 84.6%), and isthmus height (AUC, 0.941; sensitivity, 87.2%). We found no evidence of a difference between MPD and OPW in terms of the AUC and sensitivity (0.93 and 95.5%, respectively).

CONCLUSIONS

C2 pedicle screw placement on 3D-printed models is useful for performance assessment of CTA-based preoperative screw preclusion. MPD measurement with CTA multiplanar reconstruction showed the best performance for judging acceptable or unacceptable screws. However, the definition of HRVA could be modified by a 4.2 mm-internal height or by measuring only the isthmus height for judging the preclusion of C2 pedicle screw placement.

3D printing in spine care: A review of current applications

3D printing (3DP) has been brought to medical use since the early part of this century- but it has been widely researched on and publicized only in the last few years. Amongst patients with spinal disorders, 3DP has been utilized in various facets of patient care. These include pre-operative aspects - such as patient education, resident training, pre-operative planning and simulations, intra-operative assistance in the form of customized jigs for pedicle screw insertion, patient specific interbody cages and vertebral body substitutes in complex malignancies and spinal infections. It has also been utilized in deformity surgeries and has opened new avenues in minimally invasive spine care. Guidelines have now been drafted by various organizations including the FDA with a prime focus on quality control measures applicable to this new technology. There has been a recent surge in publications supporting the use of 3DP in spinal disorders, reporting an improvement in various aspects of patient care. As the technology spreads out its wings further, more innovations and applications are expected to unfold in the coming years. Considering the rapid advances that 3DP has made, having a basic understanding of this technology is imperative for all spine surgeons. Despite promising preliminary results, there still exist a few pitfalls of the technology which have hindered the universal application of 3DP. Most importantly, there is a dearth of data related to long term outcomes supporting its clinical use. The prohibitive cost of 3D models, the specialized manpower it necessitates and the need for specific instrumentation are major deterrents to widespread use of this technology, particularly in small-scale healthcare setups. With further advancements in technology, the goal must be to make it more accurate and affordable to hospitals and patients so that the benefits of the technology can reach a wider patient population.

Posterior atlantoaxial internal fixation using Harms technique assisted by 3D-based navigation robot for treatment of atlantoaxial instability

Background

To evaluate the accuracy of screw placement using the TiRobot surgical robot in the Harms procedure and to assess the clinical outcomes of this technique.

Methods

This retrospective study included 21 patients with atlantoaxial instability treated by posterior atlantoaxial internal fixation (Harms procedure) using the TiRobot surgical robot between March 2016 and June 2021. The precision of screw placement, perioperative parameters and clinical outcomes were recorded. Screw placement was assessed based on intraoperative guiding pin accuracy measurements on intraoperative C-arm cone-beam computed tomography (CT) images using overlay technology and the incidence of screw encroachment identified on CT images.

Results

Among the 21 patients, the mean age was 44.8 years, and the causes of atlantoaxial instability were os odontoideum (n = 11), rheumatoid arthritis (n = 2), unknown pathogenesis (n = 3), and type II odontoid fracture (n = 5). A total of 82 screws were inserted with robotic assistance. From intraoperative guiding pin accuracy measurements, the average translational and angular deviations were 1.52 ± 0.35 mm (range 1.14–2.25 mm) and 2.25° ± 0.45° (range 1.73°–3.20º), respectively. Screw placement was graded as A for 80.5% of screws, B for 15.9%, and C for 3.7%. No complications related to screw misplacement were observed. After the 1-year follow-up, all patients with a neurological deficit experienced neurological improvement based on Nurick Myelopathy Scale scores, and all patients with preoperative neck pain reported improvement based on Visual Analog Scale scores.

Conclusions

Posterior atlantoaxial internal fixation using the Harms technique assisted by a 3D-based navigation robot is safe, accurate, and effective for treating atlantoaxial instability.

Comparison of Perpendicular to the Coronal Plane versus Medial Inclination for C2 Pedicle Screw Insertion Assisted by 3D Printed Navigation Template

OBJECTIVE

C2 pedicle screw insertion is very important in posterior upper cervical surgery. The traditional screw placement technique requires us to consider both medial inclination and cephalad angle, it is difficult to operate intraoperatively. This paper is to explore a novel method of C2 pedicle screw placement compared with traditional C2 pedicle screw.

METHODS

A total of 44 patients diagnosed with atlantoaxial fracture or instability from May 2018 to November 2020 were involved in this retrospective study, and they were divided into C2-PPS group (perpendicular to the coronal plane C2 screw, 24 patients) and C2-TPS group (traditional C2 pedicle screw, 20 patients). The diameter of the maximum tangential circle, distance between geometric center and median sagittal plane and screw length of PPS and TPS were measured based on the 3D model of C2, respectively. Then the 3D printed navigation templated were designed and manufactured by 3D printing to assisted the PPS and TPS placement, respectively. The surgical time and radiation exposure times during operation were recorded; the post-operative grading criteria, deviation of screw entry point and deviation of screw angle of two groups were evaluated, respectively.

RESULTS

A total of 48 screws were inserted in the C2-PPS group, and 40 screws were inserted in the C2-TPS group. There were 46 screws with grade 0 (95.8%) in the PPS group and 31 screws with grade 0 (77.5%) in the TPS group, (P = 0.03). The radiation exposure times in the C2-PPS group and C2-TPS group were 4.7 ± 1.5 and 7.8 ± 3.8, respectively, (P = 0.045). The deviations of screw entry point in the C2-PPS group and C2-TPS group were 1.2 ± 0.8 mm and 3.2 ± 1.3 mm, respectively; the deviations of screw angle in the C2-PPS group and C2-TPS group were 2.1 ± 1.6° and 4.8 ± 2.0°, respectively, (P = 0.000). The diameters of the maximum tangential circle in the C2-PPS group and C2-TPS group were 5.5 ± 1.0 mm and 5.3 ± 0.9 mm, respectively. The distances between the geometric center and median sagittal plane in the C2-PPS group and C2-TPS group were 15.4 ± 2.3 mm and 18.0 ± 3.3 mm, respectively; The screw lengths in the C2-PPS group and C2-TPS group were 25.9 ± 3.2 mm and 27.6 ± 3.7 mm, respectively, (P = 0.000).

CONCLUSION

Eighty percent of C2-PPS corridor can accommodate a 3.5 mm diameter screw, and with an average screw length of 26 mm. Navigation templates assisted the C2-PPS placement is less surgical time, less radiation exposure times, more safe and more accurate than C2-TPS.

Clinical applications and prospects of 3D printing guide templates in orthopaedics

Background

With increasing requirements for medical effects, and huge differences among individuals, traditional surgical instruments are difficult to meet the patients' growing medical demands. 3D printing is increasingly mature, which connects to medical services critically as well. The patient specific surgical guide plate provides the condition for precision medicine in orthopaedics.

Methods

In this paper, a systematic review of the orthopedic guide template is presented, where the history of 3D-printing-guided technology, the process of guides, and basic clinical applications of orthopedic guide templates are described. Finally, the limitations of the template and possible future directions are discussed.

Results

The technology of 3D printing surgical templates is increasingly mature, standard, and intelligent. With the help of guide templates, the surgeon can easily determine the direction and depth of the screw path, and choose the angle and range of osteotomy, increasing the precision, safety, and reliability of the procedure in various types of surgeries. It simplifies the difficult surgical steps and accelerates the growth of young and mid-career physicians. But some problems such as cost, materials, and equipment limit its development.

Conclusions

In different fields of orthopedics, the use of guide templates can significantly improve surgical accuracy, shorten the surgical time, and reduce intraoperative bleeding and radiation. With the development of 3D printing, the guide template will be standardized and simplified from design to production and use. 3D printing guides will be further sublimated in the application of orthopedics and better serve the patients.

The translational potential of this paper

Precision, intelligence, and individuation are the future development direction of orthopedics. It is more and more popular as the price of printers falls and materials are developed. In addition, the technology of meta-universe, digital twin, and artificial intelligence have made revolutionary effects on template guides. We aim to summarize recent developments and applications of 3D printing guide templates for engineers and surgeons to develop more accurate and efficient templates.

Computed tomography comparison study of two Axis-based C1 transpedicular screw trajectory designs

BACKGROUND CONTEXT

To our knowledge, there is no comparison study of two different Axis-based C1 transpedicular screw trajectory (TST) designs.

PURPOSE

To compare two different Axis-based C1 TST designs.

STUDY DESIGN

The computed tomography (CT) morphologic analysis of the two different C1 Axis-based TST designs.

METHODS

Firstly, the design of Axis C/M and related measurements were made on a work station by using neck computed tomography angiography (CTA) data of 62 patients. The central axes (Axis M and Axis C) of C1 TST were designed by multiplanar reconstruction (MPR) technique. Based on Axis M and Axis C, the following parameters were measured: (A, A'), distance between the insertion point (IP) and the midline. (B, B'), distance between IP and the inferior aspect of C1 posterior arch. (C, C'), distance between IP and the C1 anterior cortex of the lateral mass along Axis M/C. (D, D'), insertion angle (IA) based on Axis M/C. (E, E'), the narrowest width of the inner medullary cavity (IMC) along Axis M/C.

RESULT

The C1 TST can be designed by MPR technique based on CT volume scan. The design of Axis C trajectory was easier to Axis M trajectory. A, A' were 20.7±1.6mm and 20.6±1.9mm. Both B, B' were 2.0±0.6mm. C, C' were 27.2±2.1mm and 27.5±2.1mm. D, D' were 9.9±5.0°and 10.4±7.7°. E, E' were 5.0±1.3mm and 5.4±1.4mm. Among 62 patients (124 sides), Axis C can be achieved by medial inclination, perpendicular, lateral inclination method in 81.5%, 13.7%, 4.8% sides, respectively; Axis M can be achieved by medial inclination, perpendicular, lateral inclination method in 90.3%, 8.9%, 0.8% sides, respectively.

CONCLUSION

Axis C can be a reliable trajectory for C1 transpedicular screw insertion as long as there is no displaced fracture in the C1 pedicle and lateral mass. Because of the individual differences, the ideal C1 TST can be achieved by medial inclination, perpendicular or even lateral inclination method, although its inclination direction is medial in the majority of patients.

Anatomical Study on the Safety of Anterior Cervical Craniovertebral Fusion with Clival Screw Placement in Children Aged 1-6 Years

Objective

This study aimed to investigate the safety of clival screw placement in children aged 1–6 years.

Methods

The cranial computed tomography data of 92 children aged 1–6 years were divided into three groups, according to age, for three-dimensional reconstruction. Three clival screw placement points were defined: (1) median point A at the middle and upper third of the tripartite distance from the spheno-occipital synchondrosis to the base of the skull; (2, 3) critical points B and C on the horizontal line with point A, where the screw placement passage was parallel to the sagittal plane. Parameters such as the passage length and angle were measured for horizontal, vertical facial, and extreme screw placement.

Results

The length parameters of the clival screw placement increased with age, and the screw passage length was the shortest for the vertical facial type in each age group. There were significant differences in all three groups between the length of screw placement in the vertical bone surface, the length of screw placement in the horizontal direction, and the length of screw placement on the limit at points A, B, and C (P < 0.05); the length of screw placement on the vertical bone surface was the shortest. There was no significant difference between the horizontal screw length at point A and the extreme screw length (P > 0.05). The difference between the horizontal screw length and the extreme screw length in the groups aged 1–2 years and 5–6 years was statistically significant (P < 0.05), and the horizontal screw length was longer.

Conclusion

The cranial slope of children aged 1–6 years has the morphological basis for the placement of 3.5 mm screws, and each placement point has a safe angle range for screw placement.

A Minimally Invasive Technique Using Cortical Bone Trajectory Screws Assisted by 3D-Printed Navigation Templates in Lumbar Adjacent Segment Degeneration

Purpose

Revision surgery for adjacent segment degeneration (ASD) commonly requires exposing and removing the original fixation. To minimize trauma and to reduce the operation time and blood loss, we introduced a minimally invasive lumbar revision technique using cortical bone trajectory (CBT) screws assisted by three-dimensional (3D)-printed navigation templates.

Methods

From April 2017 to October 2019, 18 patients with ASD underwent revision surgery with CBT screws assisted by 3D-printed templates in our hospital. All surgical data, including the operation time, blood loss, and incision length, were recorded. We evaluated the clinical efficacy using the visual analog scale (VAS), the Oswestry Disability Index (ODI), and the Japanese Orthopedic Association (JOA) score. X-ray and computed tomography (CT) scans were used to evaluate the stability of CBT screw fixation, the accuracy of screws, and the fusion rate.

Results

The mean follow-up was 22.4±4.7 months (12–31 months). The VAS, ODI, and JOA scores were analyzed by SPSS 21.0 and showed significant improvement at 2 weeks and the last follow-up compared with preoperative data (P<0.05). Seventy-six CBT screws were inserted with navigation templates; 2 screws were Grade B, and the other screws were Grade 0 or A. Changes in intervertebral height showed good stability of CBT screw fixation (P>0.05). All the patients exhibited satisfactory fusion results.

Conclusion

Revision surgery for ASD with CBT screws assisted by 3D-printed navigation templates has satisfactory clinical efficacy with the advantages of a short operation time, a small incision, and less blood loss.

Three-dimensional anatomic analysis and navigation templates for C1 pedicle screw placement perpendicular to the coronal plane: a retrospective study

OBJECTIVE

To explore the corridor for atlas pedicle screw placement perpendicular to the coronal plane and to develop patient-specific navigation templates for pedicle screw placement.

METHODS

This study is a retrospective analysis. A total of 71 patients (41 males and 30 females) were involved in this study from June 2016 to June 2018, and they were divided into a template group (39 patients) and a conventional group (32 patients). The CT-based 3D reconstruction models were analyzed in the template group. From the perspective of the 3D atlas in a coronal view, the pedicle corridor was obtained. Taking the center of the tangential circle of the pedicle as the entry point, we simulated screw placement perpendicular to the coronal plane. Then, the individual navigation template was designed and used in surgery. In the conventional group, free-hand pedicle screw placement was performed perpendicular to the coronal plane. The diameter of the maximum tangential circle and screw length of the pedicle corridor were measured in the template group. The surgical time, radiation exposure time, screw grading criteria and so on were evaluated and compared between the two groups after surgery.

RESULTS

;The diameter of the maximum tangential circle and the distance between the entry point and posterior tubercle were significantly greater in males than in females. The operation was successfully completed in all patients, without aggravation of nerve injury, and the follow-up was 12-20 months, with an average of 15.6 months. A total of 78 screws were inserted in the template group, and 64 screws were inserted in the conventional group. The surgical times in the template group and conventional group were 76.47±24.44 min and 125.63±36.41 min, respectively. The radiation exposure times in the template group and conventional group were 3.51±1.77 and 10.15±4.95, respectively, and there was a significant difference between the two groups. In the template group, the deviation in the screw entry point and screw angle were 1.92±1.67 mm and 2.08±1.98°, respectively. The medial angle deviation between the left and right sides was 2.71±1.88° in the template group, which was significantly less than the deviation of 3.76±2.22° in the conventional group.

CONCLUSION

A pedicle screw trajectory perpendicular to the coronal plane can be quickly obtained based on the perspective of 3D models. The technique of screw placement perpendicular to the coronal plane assisted by navigation templates has a shorter operative time, lessintraoperative fluoroscopy and a higher safety of screw placement than traditional surgery.

Development of a Computer-Aided Design and Finite Element Analysis Combined Method for Affordable Spine Surgical Navigation With 3D-Printed Customized Template

Introduction: Revision surgery of a previous lumbosacral non-union is highly challenging, especially in case of complications, such as a broken screw at the first sacral level (S1). Here, we propose the implementation of a new method based on the CT scan of a clinical case using 3D reconstruction, combined with finite element analysis (FEA), computer-assisted design (CAD), and 3D-printing technology to provide accurate surgical navigation to aid the surgeon in performing the optimal surgical technique by inserting a pedicle screw at the S1 level.

Materials and Methods: A step-by-step approach was developed and performed as follows: (1) Quantitative CT based patient-specific FE model of the sacrum was created. (2) The CAD model of the pedicle screw was inserted into the sacrum model in a bicortical convergent and a monocortical divergent position, by overcoming the geometrical difficulty caused by the broken screw. (3) Static FEAs (Abaqus, Dassault Systemes) were performed using 500 N tensile load applied to the screw head. (4) A template with two screw guiding structures for the sacrum was designed and manufactured using CAD design and 3D-printing technologies, and investment casting. (5) The proposed surgical technique was performed on the patient-specific physical model created with the FDM printing technology. The patient-specific model was CT scanned and a comparison with the virtual plan was performed to evaluate the template accuracy

Results: FEA results proved that the modified bicortical convergent insertion is stiffer (6,617.23 N/mm) compared to monocortical divergent placement (2,989.07 N/mm). The final template was created via investment casting from cobalt-chrome. The template design concept was shown to be accurate (grade A, Gertzbein-Robbins scale) based on the comparison of the simulated surgery using the patient-specific physical model and the 3D virtual surgical plan.

Conclusion: Compared to the conventional surgical navigation techniques, the presented method allows the consideration of the patient-specific biomechanical parameters; is more affordable, and the intraoperative X-ray exposure can be reduced. This new patient- and condition-specific approach may be widely used in revision spine surgeries or in challenging primary cases after its further clinical validation.