Researchers have adapted a standard glue gun to 3D print a bone-like material directly onto fractures, opening new possibilities for use in the operating room.
The device, which has been tested so far in rabbits, promises to enhance the precision and speed of treating complex or irregular bone injuries.
Traditional methods for fixing large or complicated fractures usually involve bone grafts and metal hardware such as pins or plates, which are often not customised to suit patients’ unique anatomy.
This mismatch can cause misalignment and instability, extending recovery time or impairing healing.
Although customised 3D-printed grafts have been investigated, their lengthy production times have limited their use during surgery.
This new technique, recently described in the journal Device, employs a portable extrusion device that utilises a PCL/HA composite material to print directly onto a fracture site.
The composite, supported by temperature-controlled components, enables the precise creation of a scaffold that integrates seamlessly with native tissue.
In vivo tests demonstrated that the PCL/HA composite maintains its structural integrity, supports new bone formation, and exhibits superior performance compared to traditional bone cement in terms of tissue growth and bone density.
Histological analyses showed no signs of tissue necrosis or abnormal inflammation after applying the composite to rabbit femoral fractures; importantly, the device’s adjustable parameters, such as HA content and temperature, enable customisation based on the specific needs of the defect.
This flexibility suggests the technology could be tailored for various bone sizes, shapes, and healing timelines, providing a patient-specific, ready-to-implant solution during surgery.
Despite its potential, the researchers recognise that several challenges still need to be addressed before clinical use.
Improvements in composite materials to boost long-term stability and adhesion are necessary, possibly by adding polymers or adhesive agents.
Optimising extrusion techniques, including tip designs and temperature settings, could further improve compatibility with complex or irregular geometries.
Incorporating porogens into the composite also supports nutrient exchange and promotes osteogenesis.
An exciting aspect of this technology is the possibility of delivering antibiotics locally to reduce postoperative infections, considered one of the biggest challenges in orthopaedic surgery.
The in situ printing platform could embed antimicrobial agents within the scaffold, offering sustained release to reduce infection risks and improve patient outcomes.
Looking ahead, more comprehensive in vivo studies, including large-animal models and infection simulations, are crucial.
However, authors believe its integration into surgical practice could simplify fracture fixation, reduce operation times and promote better healing – especially in cases where traditional implants are not ideal.
