Picture an operating theatre filled with medical equipment and a team of surgeons in utmost concentration. On the table lies a patient with a complex femoral fracture. In the surgeon’s hand is an unexpected tool—not one typically found among scalpels, scissors and sterilised gauze. It resembles an ordinary glue gun used in crafts, yet it holds the promise of saving lives. The doctor directs the device at the fracture site and begins tracing precise lines, forming cohesive layers of a biocompatible material that take shape before the medical team’s eyes as a custom-designed bone scaffold.
No longer science fiction, but established scientific fact, researchers have developed a portable device similar to a glue gun that prints bone scaffolds directly into fracture sites during surgery. The technology employs a blend of biocompatible polycaprolactone and hydroxyapatite, and can also be loaded with antibiotics that are gradually released to prevent infection.
This innovation builds upon earlier milestones in orthopaedic 3D printing, such as the production of custom joints and plates, and the repair of complex fractures. Now, the process of personalisation has gone a step further, with the ability to print directly during surgery.
The device heats a composite filament of hydroxyapatite and polycaprolactone to around 60 degrees Celsius, softening it just enough for safe application without harming living tissue. The surgeon applies it over the fracture, layering material that hardens instantly into a structure replicating the bone’s shape. By adjusting the ratio of the two materials, the scaffold’s strength and rigidity can be tailored to suit the treatment site.
Preclinical trials in rabbits showed faster and more effective healing compared to conventional methods, with no signs of inflammation or necrosis afterwards
The scaffold can also be infused with antibiotics such as vancomycin and gentamicin, which are released in a controlled manner to provide localised infection protection. Preclinical trials in rabbits showed faster and more effective healing compared to conventional methods, with no signs of inflammation or necrosis during follow-up assessments. Designed to biodegrade over time and be replaced by natural bone, the printed scaffold eventually becomes part of the patient's body.
The approach also shortens surgery times by eliminating the need for pre-manufacturing and allows for a customised fit, even in irregular fractures. As it enters clinical trials, this technology is poised to transform the treatment of complex bone injuries, offering quicker, more cost-effective and more efficient outcomes.
Decades of development
Three-dimensional printing did not emerge overnight. It is the culmination of decades of development dating back to the 1980s. Today, it is revolutionising industries from medicine and manufacturing to aerospace and space exploration.
In 1981, Japanese researcher Hideo Kodama published the first scientific paper on solidifying layers of liquid material using ultraviolet light to fabricate models. Although his invention did not gain widespread attention at the time, it laid a critical foundation. In 1984, American innovator Chuck Hull patented stereolithography, the first practical 3D printing method using lasers to cure liquid resin. Hull is now widely regarded as the pioneer of the technology.
An intricate geometric form made of clear resin and dried with laser light is in the process of being printed in the Form 2 desktop 3D printer by Formlabs, at CES 2016 in Las Vegas, Nevada, January 7, 2016.
The 1990s saw the advent of industrial-scale 3D printing. Leading companies introduced techniques such as fused deposition modelling and selective laser sintering. Early applications focused on prototyping in the automotive and aerospace sectors, cutting both time and costs relative to traditional manufacturing methods.
As patents expired in the early 2000s, smaller companies and academic researchers began to develop open-source printers. In 2005, the launch of the RepRap project—an open-source effort to create self-replicating printers—made 3D printing more affordable and accessible.
Between 2010 and 2020, the technology became increasingly widespread across a wide range of sectors. In medicine, applications extended from prosthetics and bone implants to experimental organ printing using living cells. In architecture, companies in China and Europe constructed homes using 3D-printed concrete. In space, both government agencies and private firms adopted 3D printing for producing spare parts aboard the International Space Station.
By 2025, the 3D printing industry had grown into a multi-billion-dollar sector encompassing electronics, fashion, food production and defence.
Personalised prosthetics
In the medical field, 3D printing has ushered in a new era of personalised prosthetics and implants tailored to individual patients. Unlike standardised off-the-shelf models, this technology enables the creation of limbs and implants that conform precisely to the patient's anatomy, significantly improving fit and functionality. Traditional prosthetics often posed challenges in terms of comfort and usability, leading some patients to abandon them altogether.
There are now lightweight, flexible prosthetic limbs and parts made from biocompatible materials.
Today, digital design can be modified rapidly, and parts can be reprinted within hours. Designs are refined in real time based on feedback from surgeons and patients, creating a continuous loop of enhancement.
Modern prosthetics and replacement components are lightweight, flexible and made from biocompatible materials. They offer improved comfort and enhanced performance for users.
This evolution is also reflected in economic projections. The medical 3D printing market is expected to grow at an annual growth rate of more than 20%, driven by the advantages of personalisation, reduced costs and faster production timelines.
Speaking exclusively to Al Majalla, Professor Ian Gibson, a design engineering expert at the University of Twente in the Netherlands, described the transformative impact of 3D-printed implants. "The greatest benefit is their anatomical precision, which reduces rejection and inflammation. They also improve aesthetic outcomes, especially for facial implants."
"Compatibility with bone mechanics is another key advantage, preventing bone density loss. Porous structures reduce weight and enhance bone integration. As adoption spreads, we will see faster, more individualised treatments for patients."
