3D-Printed Titanium Prosthesis Saves Patient's Leg After Sarcoma Diagnosis

A 38-year-old patient diagnosed with tibial sarcoma was at risk of losing his leg. Surgeons at Gregorio Marañón Hospital in Madrid managed to avoid amputation, however, through an innovative bone implant custom-made specifically for him.

This is the first personalised prosthesis of its kind made from metamaterial — a technology originally adopted from the aerospace industry. The titanium structure is manufactured using 3D printing and replicates the mechanical properties of natural bone.

Unlike conventional prostheses, which replace bone with a solid component, this implant recreates the architecture and strength of bone through a network of fine titanium rods that distribute weight in a manner similar to bone tissue. As a result, the patient retained both his leg and his knee.

The special design encourages the patient's own bone to grow and integrate with the prosthesis, reducing the risk of rejection and complications. Because it is 3D-printed and tailored to each individual patient, the technology also cuts surgery time in half.

Weighing just 300 grams, the implant can withstand more than 500 kilograms according to simulations — compared to conventional prostheses, which weigh several kilograms and can only bear 100–150 kilograms.

One year after the operation, the patient is already able to walk. After nearly two years of being unable to bear weight on the affected leg, he said he is finally regaining his mobility.

Gregorio Marañón Hospital has already performed a second similar procedure and is preparing two further personalised implants — one for the wrist and another for the sternum. The medical team's goal is to introduce this hyper-personalised medicine technology into the public health system.