Case Study: Salzburg University Hospital achieves personalized cranial reconstruction with 3D Systems' 3D-printed PEEK implant

Salzburg University Hospital performs successful cranioplasty using a 3D printed PEEK cranial plate

Salzburg University Hospital, working with vendor 3D Systems, faced a long-standing challenge in helping a 55-year-old patient with a congenital skull anomaly that caused significant asymmetry, psychological distress, and difficulty finding a suitable corrective option. Traditional surgery had been limited by technical and financial barriers, and the team needed a custom implant that was lightweight, biocompatible, thermally stable, and aesthetically precise.

Using 3D Systems’ EXT 220 MED printer and PEEK material for point-of-care additive manufacturing, the hospital created a custom 3D-printed cranial plate with a honeycomb structure that reduced weight by about 40% and could be produced in just 10 hours. 3D Systems enabled Salzburg University Hospital to complete the cranioplasty successfully, improving the patient’s physical appearance, confidence, and quality of life, while also establishing a repeatable workflow for future patient-specific implants.

Salzburg University Hospital

Rainer Trummer

Computer Scientist