Custom Lower Limb Implants

While Meshworks’ design and production platform can be used for the production of customised orthopaedic implants for various parts of the anatomy, the company initially focussed its skills on foot and ankle surgery, where there is a demand that is not fulfilled in the UK with a cost-effective, agile and rapid solution.
Many surgeons understand the role that additive manufacturing must play in the production of patient-specific implants, and we are equally aware that for many the cost is prohibitive and the production times too long.
While maintaining excellence in all aspects of implant design and manufacture, and adhering to stringent regulatory and quality control requirements, Meshworks overcomes the cost and time issues that have been a barrier for surgeons to embrace this crucial process for the production of custom implants.
Meshworks is able to provide various types of foot and ankle implants, including:

Keystone

Following avascular necrosis, trauma, or tumour in the body of the talus, the talus may need to be replaced. The Keystone implant is designed specifically to replace the diseased talus whilst preserving the calcaneus. Implants can be fixed with standard hindfoot nails and cannulated screws.

Articulating Keystone

The talus replacement implant with an articulating surface can be useful following trauma or failure of total ankle replacement surgery. The polished surface moves smoothly against the remaining navicular to preserve motion in the patient’s foot.

Sphere

Spherical implants are a versatile option, offering a way to correct deformity in indications such as plafond or talus pathology. Custom spherical implants offer an alternative to femoral head allograft in tibiotalocalcaneal arthrodesis that may improve success rates1.
Custom Talus

Custom Talus Spacer

Patient-specific Custom Talus Spacers (CTS) are additively manufactured implants that are used in talus replacement surgery. The Custom Talus Spacer is made for each patient individually, is modelled from computed tomography (CT) imaging, and is fitted to a patient’s specific anatomy. The Talus Spacer is a fully-articulating talus replacement which allows patients to retain full movement. It is a solid, fully polished implant that does not fuse with surrounding bone.

The CTS implant is made of solid titanium alloy (Ti-6Al-4V) and replicates the biomechanical function of the talus. The major articulating surfaces to surrounding bones (Tibia, Calcaneus, Navicular) are recreated as required. The structure is designed to replicate patient anatomy, while minimising small cavities (with high radius of curvature). The implants are highly polished and coated with Titanium Nitride (TiN) to improve wear resistance and articulation.

10.1053/j.jfas.2019.10.015
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Custom Cage

Following avascular necrosis, trauma, or tumour, the bone may need to be replaced. The fusion cage implant is designed specifically to replace diseased bone whilst preserving surrounding tissue. Implants can be fixed with standard intramedullary nails and screws. The fusion cage can also be provided with an articulating surface which can be useful following trauma or failure of total joint replacement surgery. The polished surface moves smoothly against the remaining joint to preserve motion.

Custom Spacer

Patient-specific are typically used in talus replacement surgery. The Spacer is made for each patient individually and modelled from computed tomography (CT) imaging, fitted to a patient’s specific anatomy. It is a fully-articulating replacement which allows patients to retain full movement. The structure is designed to replicate patient anatomy, while minimising small cavities (with high radius of curvature). The implants are highly polished and coated with Titanium Nitride (TiN) to improve wear resistance and articulation.

Design and Manufacturing Process

The Meshworks design and manufacturing process combines advanced technologies, dedicated design skills and metal additive manufacturing to produce custom implants of the highest quality quickly and efficiently.
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Indications

Foot and ankle custom orthopaedic implants offer an alternative treatment method in cases which normally would be managed by complex limb salvage efforts or more extreme approaches such as amputation.
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Timeline

After prescription, Meshworks designs, manufactures, and delivers implants to your hospital within 4 weeks, or even quicker for urgent cases.
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Animal Study

Meshworks implants are designed to facilitate bone ingrowth, promoting long-term stability of the implant. In a 12-week ovine study of implantation into the femoral condyle, bone grew within the struts making up a cylindrical Meshworks’ implant.
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