Case Study: Exactech improves ankle replacement planning and OR efficiency with 3D Systems patient-specific guides

Exactech gains the competitive edge with effective patient-specific instrumentation and surgical planning

Exactech, a global medical technology company focused on orthopaedic implants and smart surgical technologies, wanted to help surgeons achieve better outcomes in total ankle replacement. To address ongoing risks such as subsidence, implant loosening, bone cysts, and impingement—and to reduce time in the operating room—Exactech partnered with 3D Systems to explore patient-specific instrumentation (PSI) and surgical planning for its Vantage Total Ankle System.

3D Systems and Exactech developed the Vantage Ankle PSI solution, combining pre-surgical planning, a planning portal, and patient-specific 3D-printed guides manufactured with SLS and DuraForm ProX PA material. The solution has been widely adopted, with about 50% of ankle cases now using PSI, and surgeons report greater confidence, highly detailed pre-op plans, improved tissue preservation, and a simplified procedure process with the potential to reduce OR time.

Exactech

Devan Carter

Director of Marketing