Printing Technology Research Articles

Electrochemical Biosensors 3D Printed by Fused Deposition Modeling: Actualities, Trends, and Challenges

The technology of 3D printing, particularly fused deposition modeling (FDM) 3D printing, has revolutionized the development of electrochemical biosensors, offering a versatile and cost-effective approach for clinical applications. This review explores the integration of FDM in fabricating biosensing platforms tailored for clinical diagnostics, emphasizing its role in detecting various biomarkers and viral pathogens. Advances in 3D printing materials, especially the emergence of bespoke conductive filaments, have allowed the production of highly customizable and efficient biosensors. A detailed discussion focuses on the design and application of these biosensors for viral detection, highlighting their potential to improve diagnostic accuracy. Furthermore, the review addresses current trends, including the push towards miniaturization and multianalyte detection, alongside challenges such as material optimization and regulatory hurdles. By providing a comprehensive overview, this work underscores the transformative impact of 3D-printed electrochemical biosensors in clinical diagnostics while also identifying critical areas for future research and development.

Enhancing perioperative planning: three-dimensional printing templating in orthopaedic surgery

<p><strong>Aim</strong> 3D printing technology revolutionises orthopaedic surgery by creating accurate patient-specific models, surgical guides, and implants. The COVID-19 pandemic accelerated this trend, allowing localized solutions and biocompatible materials to replicate bone geometric complexity, enabling surgeons to plan and rehearse surgeries. This study aims to illustrate the use of 3D printing in the preoperative planning of a complex distal femur fracture.<br /><strong>Methods</strong> A 42-year-old woman with a complicated Gustilo-Anderson grade III-A fracture underwent 3D printing for implant planning, contouring, and screw trajectory visualization. The procedure took seven hours, and the surgery lasted only two hours, with no complications or complaints during a one-month follow-up.<br /><strong>Results</strong> 3D printing has revolutionized orthopaedic surgery by better visualizing complex fractures, reducing surgical time, and enhancing precision. Traditional 2D imaging techniques struggle to capture intricate details, requiring 3D printing for accurate preoperative planning and implant selection. However, challenges include high costs, time, and specialized training. Further research is needed to understand long-term outcomes.<br /><strong>Conclusion</strong> The benefits of 3D printing in orthopaedic surgery, including improved visualization, reduced time, and improved precision, highlight its potential for further advancement.</p>

Personalized Medicine Through Semisolid-Extrusion Based 3D Printing: Dual-Drug Loaded Gummies for Enhanced PatientCompliance.

The purpose of this research was to develop and characterize dual-drug Isoniazid-Pyridoxine gummies using Semisolid Extrusion (SSE) 3D printing technology, aimed at personalized dosing for a broad patient demographic, from pediatric to geriatric. This study leverages SSE 3D printing, an innovative approach in personalized medicine, to enable precise dose customization and improve patient adherence. By formulating dual drug-loaded gummies, the research addresses the challenges of pill burden and poor palatability associated with traditional tuberculosis regimens, ultimately enhancing the therapeutic experience and effectiveness for patients across various age groups. Gummies were formulated using varying ratios of gelatin, carrageenan, and xylitol, and printed using the BIO X 3D printer. Rheological properties were evaluated to confirm printability, shear-thinning behavior, and viscosity recovery. In vitro drug release and stability were assessed under refrigerated (5 ± 3°C) and ambient (25 ± 2°C) storage conditions. FT-IR spectroscopy was used to examine drug-excipient interactions. The optimized F3 formulation, containing 900 mg Isoniazid and 30 mg Pyridoxine, demonstrated successful printability and structural integrity. Over 80% of both drugs were released within 30 min. Rheological testing confirmed ideal shear-thinning and viscoelastic properties for extrusion-based printing. Suitable textural properties for pediatric patient compliance were observed. Stability studies showed that both drug content and release profiles remained consistent for 30 days under refrigerated storage. This study determines the potential of SSE 3D printing in fabricating personalized Isoniazid-Pyridoxine-loaded gummies, offering a novel, patient-friendly dosage form for tuberculosis treatment. The optimized formulation exhibited excellent printability, stability, and rapid drug release, positioning 3D-printed gummies as a promising alternative to conventional oral dosage forms in enhancing patient adherence.

High-efficiency focusing metalens based on metagrating arrays

The flexible and precise control of wavefronts of electromagnetic waves has always been a hot issue, and the emergence of metasurfaces has provided a platform to solve this problem, but their design and optimization remain challenging. Here, we demonstrate two design and optimization methods for metagrating-based metalenses based on the highest manipulation efficiency and highest diffraction efficiency. The metalens operating at 0.14 THz with numerical apertures of 0.434 is designed by these two methods for comparison. Then, the metalens is fabricated with photocuring 3D printing technology and an imaging system is built to characterize the distribution of focal spots. With the highest manipulation efficiency, the metalens shows a focal spot with the diameter of 0.93λ and depth of focus (DOF) of 22.7λ, and the manipulation and diffraction efficiencies reach 98.1% and 58.3%. With the highest diffraction efficiency, the metalens shows a focal spot with the diameter of 0.91λ and DOF of 24.6λ, and the manipulation and diffraction efficiencies reach 94.6% and 62.5%. The results show that the metalenses designed by both methods can perform a filamentous focal spot in the sub-wavelength scale with a long DOF; simultaneous high manipulation and diffraction efficiencies are obtained. A transmission imaging manner is used to verify the imaging capability of the metalenses, and the measurements are satisfactorily congruous with the anticipated results. The proposed methods can stably generate focal spots beyond the physical diffraction limit, which has a broad application in terahertz imaging, communications, etc.

Mixed-Dimensional Semiconductors-Based Ternary Circuits with Tunable Negative Transconductance Characteristics.

Multivalued logic (MVL) systems, in which data are processed with more than two logic values, are considered a viable solution for achieving superior processing efficiency with higher data density and less complicated system complexity without further scaling challenges. Such MVL systems have been conceptually realized by using negative transconductance (NTC) devices whose channels consist of van der Waals (vdW) heterojunctions of low-dimensional semiconductors; however, their circuit operations have not been quite ideal for driving multiple stages in real circuit applications due to reasons such as a reduced output swing and poorly defined logic states. Herein, we demonstrate ternary inverter circuits with near rail-to-rail swing and three distinct logic states by employing vdW p-n heterojunctions of single-walled carbon nanotubes (SWCNT) and MoS2 where the SWCNT layer completely covers the MoS2 layer. In particular, SWCNTs are inkjet printed to form heterojunctions with MoS2 grown by chemical vapor deposition (CVD), and both inkjet printing and CVD are fully scalable device fabrication methods for low-dimensional materials. In addition, the NTC characteristics of heterojunction field-effect transistors (H-FETs) are explained based on the electrical characteristics of individual SWCNT and MoS2 channels. By adjustment of the p-channel characteristics in H-FETs by exploiting the advantages of the inkjet printing technology, the widths of the NTC regions are easily adjusted accordingly. The extended NTC region enables stable middle logic state operations of low-dimensional semiconductors-based ternary inverters over a sufficiently wide input voltage range.

Effect of different 3D-printing systems on the flexural strength of provisional fixed dental prostheses: a systematic review and network meta-analysis of in vitro studies

ObjectivesThe aim of this systematic review and network meta-analysis was to compare the flexural strength of provisional fixed dental prostheses (PFDPs) fabricated using different 3D printing technologies, including digital light processing (DLP), stereolithography (SLA), liquid crystal display (LCD), selective laser sintering (SLS), Digital Light Synthesis (DLS), and fused deposition modeling (FDM).Materials and methodsA comprehensive literature search was conducted in databases including PubMed, Web of Science, Scopus, and Open Grey up to September 2024. Studies evaluating the flexural strength of PFDPs fabricated by 3D printing systems were included. A network meta-analysis was performed, using standardized mean differences (SMDs) and 95% confidence intervals (CIs) to assess the effects of each system on flexural strength.ResultsA total of 11 in vitro studies were included, with 9 studies contributing to the network meta-analysis. SLS (77.70%) and SLA (63.82%) systems ranked the highest in terms of flexural strength, while DLP ranked the lowest (23.40%). Significant differences were observed between SLS and multiple other systems, including DLP (-14.58, CI: -22.67 to -6.48), LCD (-14.65, CI: -25.54 to -3.59), FDM (-12.87, CI: -23.30 to -2.52), SLA (-11.41, CI: -18.74 to -4.01), and DLS (-10.89, CI: -21.23 to -0.67). Direct comparisons were limited, with DLP vs. SLA having the most data. Other comparisons were predominantly indirect.ConclusionsSLS and SLA systems exhibited superior flexural strength compared to other systems. However, the limited number of direct comparisons and reliance on indirect evidence suggest that further research is necessary to confirm these findings.

Clinical Efficacy of Three-Dimensional-Printed Pure Titanium Fracture Plates with Locking Screw Systems in Distal Tibia Fractures

Background and Objectives: Distal tibia fractures are high-energy injuries characterized by a mismatch between standard plate designs and the patient’s specific anatomical bone structure, which can lead to severe soft tissue damage. Recent advancements have focused on the development of customized metal plates using three-dimensional (3D) printing technology. However, 3D-printed metal plates using titanium alloys have not incorporated a locking system due to the brittleness of these alloys. Therefore, this study aimed to determine whether a locking mechanism can be effectively implemented using 3D-printed pure titanium and further evaluate the clinical outcomes of such implants in patients with distal tibia fractures. Materials and Methods: Between March 2021 and June 2022, nine patients who underwent open reduction and internal fixation for distal tibia fractures using 3D-printed pure titanium plates were enrolled. Pure titanium powder (Ti Gr.2, Type A, 3D Systems, USA) was spread to a thickness of 30 μm and partially sintered using a 500 W laser to produce the 3D-printed metal plates. The locking screws were fabricated using a milling process. Open reduction and internal fixation were performed on the nine patients using 10 customized plates. The clinical efficacy was analyzed using the union rate, and complications, such as infection and skin irritation, were evaluated to ensure a comprehensive outcome assessment. Results: Surgical treatment was successfully performed on nine patients, with nine of ten plates remaining stable and undamaged. However, one patient with neurofibromatosis experienced a fractured metal plate, which necessitated revision surgery using a metal rod. No screw loosening or surgical wound complications occurred. Conclusions: This study showed that 3D-printed pure titanium plates with integrated locking screw systems provide a viable and effective solution for managing distal tibia fractures. Three-dimensional printing and pure titanium show promise for orthopedic advancements.

Next-Generation Point-of-Care Diagnostics: Silver Nanoparticle-Enhanced 3D-Printed Multiplex Electrochemical Biosensor for Detecting Dengue and Chikungunya Viruses.

In recent years, the increasing prevalence of viral infections such as dengue (DENV) and chikungunya (CHIKV) has emphasized the vital need for new diagnostic techniques that are not only quick and inexpensive but also suitable for point-of-care and home usage. Existing diagnostic procedures, while useful, sometimes have limits in terms of speed, mobility, and price, particularly in resource-constrained environments and during epidemics. To address these issues, this study proposes a novel technique that combines 3D printing technology with electrochemical biosensors to provide a highly sensitive, user-friendly, and customizable diagnostic platform. This study focuses on a unique 3D-printed electrode cassette made with fused deposition modeling technology, which ensures strong structural alignment and improved performance under a variety of environmental conditions. When combined with paper-based electrodes loaded with silver nanoparticles, the platform dramatically enhances the detection sensitivity and reliability. The biosensor uses cyclic voltammetry and electrochemical impedance spectroscopy to detect DENV and CHIKV antigens within a linear range of 1 × 102 to 1 × 106 ng/mL. Results were delivered in 20 s and stable for 30 days. The device's performance was verified by testing with blood serum samples containing both DENV and CHIKV antigens, demonstrating its capacity to properly identify coinfections. This novel diagnostic tool represents a huge step forward in accessible and efficient healthcare solutions, bridging important gaps in the global battle against arboviral infections.

The present status of research and related applications of three-dimensional printing in the field of healthcare.

As a new manufacturing technology, 3D printing technology has shown great potential in healthcare. The current study attempts to provide a comprehensive review of the current research landscape regarding the utilization of 3D printing technology in the healthcare sector. Nowadays, three-dimensional printing is applied in tissue engineering to manufacture complex and functionalized tissue scaffolds, hence providing strong support for regenerative medicine and enabling more precise tissue replacement in vivo. In the context of the manufacturing of medical models, the technology can reproduce with great accuracy the diseased organs or structures in question by the patient; in this respect, even bones are included. That gives intuitive physical models for surgical planning, simulation training, thereby improving the success rate of surgery and reducing complications. In the context of bespoke medical devices, 3D printing facilitates personalization of medical devices, such as prosthetics and implants, to a greater degree of fit for individual patient requirements. In the pharmaceutical sector, 3D printing technology is being employed to develop personalised medicines, with the objective of optimising drug release profiles in innovative ways. However, the application of 3D printing in healthcare also encounters obstacles, including the necessity to enhance the biocompatibility of the materials, achieve greater precision in printing, and establish more comprehensive standards and regulations. Nevertheless, the rapid development and wide spread of the use of 3D printing in health cannot be ruled out; more so, it is likely to change the face of healthcare in times to come

Research on the Application and Optimization of Stepper Motors in Ink jet Printers

Ink jet printers have become an indispensable tool in various fields due to their high resolution, cost-effectiveness, and versatility. The performance of these printers heavily relies on precise mechanical control. Stepper motors, as key actuators in these systems, play a vital role in ensuring smooth operation and maintaining print quality. Understanding and optimizing these components are essential for addressing the growing demands for speed, accuracy, and energy efficiency in modern printing technologies. This article explores the basic structure of ink jet printers, analyzes their application functions, and focuses on the driving mechanism of print heads and paper transport systems. Studied the components, operating modes, and principles of the stepper motors used in these devices, emphasizing their functionality based on electromagnetic induction. In addition, this article proposes optimization strategies aimed at improving the accuracy and speed control of stepper motors in ink jet printers. Experimental data shows that through these optimizations, performance and response time have been significantly improved. The research results emphasize that the integration of enhanced stepper motor technology not only improves the market competitiveness of ink jet printers, but also promotes technological innovation and industrial progress

A Brief Introduction of Inkjet Printing Technology and Optimizations

Inkjet printing technology has developed for several years, and it has made a great difference in peoples lives. The inkjet printing technology can be divided into two types, which are Continuous Inkjet (CIJ) technology and Drop-on-Demand (DOD) inkjet technology. The Drop-on-Demand inkjet includes piezoelectric inkjet, thermal inkjet, electrostatic inkjet, and acoustic inkjet. These technologies have their own benefits and weaknesses. The Drop-on-Demand printer has better precision than Continuous Inkjet. Optimizations to the printing quality can be carried out from three factors, which are the ink, the substrate, and the coffee ring effect. The ink can be improved by controlling the temperature. The substrate can be improved by changing its structure. The coffee ring effect can be suppressed by using hydro-soluble polymer additives or controlling the temperature. Future advancements in inkjet printing technology are expected to focus on optimizing these factors through interdisciplinary approaches, including material science, fluid dynamics, and advanced manufacturing techniques

The application of 3D printing in mechanical manufacturing

In modern society, with the continuous development of science and technology, 3D printing technology has become a hot technology in the field of machinery manufacturing. 3D printing can improve production efficiency, and can accurately produce three-dimensional products that can be directly applied to the mechanical parts that need to be manufactured. This article will introduce the basic principles of 3D and its advantages, but also introduce the application of 3D printing, focusing on the application of 3D printing in the construction field using cement-based materials, while printing some key components in the automotive field, fiber composite materials in the aviation field is also a development direction. This article also looks for some obvious problems with 3D printing, especially the performance of 3D printed products, as well as the cost-related issues of 3D printing, for these problems, the paper gives solutions and future directions. 3D printing will have an important position in the future, and will be widely used in the field of mechanical manufacturing and production, which has great significance

A Stable Zn(II) Metal-Organic Framework as Turn-On and Blue-Shift Fluorescence Sensor for Amino Acids and Dipicolinic Acid in Living Cells or Using Aerosol Jet Printing.

Amino acids and dipicolinic acid (DPA) are important biomarkers for identifying human health. Establishing rapid, accurate, sensitive, and simple assays is essential for disease prevention and early diagnosis. In this work, a novel Zn(II) metal-organic framework (MOF) with the formula {[Zn5(μ3-OH)2(BTDI)2(dpp)2]·dpp·4H2O·2DMF}n (JXUST-53, where JXUST denotes Jiangxi University of Science and Technology, H4BTDI = 5,5'-(benzo[c][1,2,5]thiadiazole-4,7-diyl)diisophthalic acid; dpp = 1,3-di(4-pyridyl)propane) was successfully synthesized via a mixed-ligands strategy. JXUST-53 exhibits a three-dimensional (4,10)-connected deh1 topological structure, which remains stable after soaking in aqueous solutions with different pH values (1-12) and organic solvents for at least 24 h, showing high chemical and pH stability. As a potential fluorescence sensor, JXUST-53 can specifically recognize l-threonine (l-Thr), l-histidine (l-His), and DPA in EtOH solutions through fluorescence enhancement and a blue-shift effect. It is worth noting that JXUST-53 is the first MOF-based fluorescence sensor capable of recognizing l-Thr. In addition, the university logo of JXUST with JXUST-53 deposited on it was printed by aerosol jet printing technology, enabling a portable and convenient method for monitoring DPA. More importantly, JXUST-53 has good biocompatibility and low cytotoxicity to sense l-Thr, l-His, and DPA in living cells.

Effect of Load Vector Orientation on Uniaxial Compressive Strength of 3D Photoresin

Rapid prototyping has a wide range of applications across various fields, both in industry and for private use. It enables the production of individual parts in a short time, independent of supply chains, which is particularly important in remote locations. Among all 3D printing technologies, stereolithography using photo resins is the most accessible and offers the highest printing quality. However, the strength properties of parts made from photo resins remain a critical concern. In this study, we conducted experimental research to investigate the effect of load vector orientation under uniaxial compression on the elastic and mechanical properties of 3D-printed cylindrical samples. The results revealed that samples with layers oriented at 60° to the load vector exhibited the highest strength, while those with layers at 30° to the load vector showed the lowest strength. Samples with layers aligned parallel or perpendicular to the load vector demonstrated similar strength properties. Under quasi-elastic loading, samples with layers parallel to the load vector exhibited the highest Young’s modulus and the lowest Poisson’s ratio. Conversely, samples with layers oriented at 30° to the load vector displayed the highest Poisson’s ratio. Microstructural analysis revealed that the anisotropy in the mechanical properties of the 3D-printed samples is attributed to the layered, heterogeneous structure of the photoresin, which exhibits varying degrees of polymerization along the printing axes. The upper part of each layer, with a lower degree of polymerization, contributes to the ductile behavior of the samples under shear stresses. In contrast, the lower part of the layer, with a higher degree of polymerization, leads to brittle behavior in the samples.

Particle Trajectory Simulation Facilitates the Development of an Efficient Sample Introduction System for Single-Particle ICP-MS Analysis.

Inductively coupled plasma mass spectrometry (ICP-MS) has demonstrated significant capabilities in the analysis of single events, such as single cells and particles. Researchers have been actively pursuing innovations in ICP-MS sample introduction systems to enhance their transport efficiency, as this is critical for ensuring the accuracy of single-event analysis. However, the majority of prior studies have relied heavily on empirical approaches, with limited attention given to the individual characteristics of particles from a theoretical perspective and a lack of efficient manufacturing tools for optimizing related components. Herein, we developed a high-efficiency sample introduction system for single-event ICP-MS analysis by integrating the computational simulation-aided design, precise 3D printing manufacturing, and rapid experimental testing process. For the first time, we simulated the transport trajectories of individual particles passing through the spray chamber, providing theoretical guidance for the design and optimization process. The statistical analysis of particle trajectories revealed that under the absorption boundary condition, particles between 20 and 100 nm achieved transport efficiencies exceeding 18.8%. In comparison, particles larger than 100 nm exhibited 0% transport efficiency due to increased deposition within the spray chamber. The spray chamber was fabricated in-house using a range of 3D printing technologies and materials, streamlining the process and reducing the cost for both manufacturing and validation. Further optimization of the operating parameters, including an increase in temperature, resulted in a notable transport efficiency of 61.1%. The workflow introduced in this study has the potential to transform the research and development of critical mass spectrometry components moving forward.

Porous carbons with complex 3D geometries via selective laser sintering of whey powder

In addition to the inherent limitations of carbons to melt or flow, a vast majority of carbon precursors deforms during carbonisation, with stereolithography of thermoset resins being the preferred technology for 3D printing of carbons. An alternative is now presented with the possibility of using a melting-based technology, selective laser sintering (SLS), to fabricate 3D structures that withstand carbonisation. The key factor that makes this happen is whey powder, a natural, abundant and cheap by-product of the dairy industry. When heating the whey powder with a laser at 180–200 ºC for a few seconds, whey particles sinter, and 3D structures are obtained layer-by-layer. Carbonisation of the sintered whey structures brings about 3D porous carbons with excellent mechanical properties that preserve the SLS printed form albeit an isotropic shrinkage (approx. 23%). Melanoidins are identified as responsible for both the sintering and the thermoset behaviour during carbonisation of the whey powder.

Development of Novel Monolithic Catalyst for BTEX Catalytic Oxidation Using 3D Printing Technology

Four differently shaped monolithic catalyst supports were made using 3D printing technology. Two catalytically active mixed oxides, MnFeOx and MnCuOx, were applied to the monolithic supports using the impregnation technique. Catalysts were characterized using an adhesion test, field emission scanning electron microscopy, X-ray diffraction, and Raman spectroscopy in a manner similar to the density functional theory model. Excellent mechanical stability of the catalyst layer was obtained, with catalyst mass loss under 2% after 30 min of ultrasound exposure. SEM analysis revealed that the catalyst layer was rough but homogeneous in appearance and ~6 μm thick. The presence of double oxides—FeMnO3 and CuMn2O4—as well as single oxides of Mn, Fe, and Cu was established via XRD and Raman spectroscopy. Additional theoretical calculations of Raman spectra for FeMnO3 and CuMn2O4 were performed in order to aid in the interpretation of Raman spectra. The catalytic activity of the prepared catalysts for the catalytic oxidation of a gaseous mixture of benzene, toluene, ethylbenzene, and o-xylene (BTEX) was investigated. The monolithic support with the most complex shape and, consequently, the greatest surface area proved to enable the highest efficiency, while both catalysts performed well having similar conversions.

3D printing of different fibres towards HA/PCL scaffolding induces macrophage polarization and promotes osteogenic differentiation of BMSCs.

With the rise of bone tissue engineering (BET), 3D-printed HA/PCL scaffolds for bone defect repair have been extensively studied. However, little research has been conducted on the differences in osteogenic induction and regulation of macrophage (MPs) polarisation properties of HA/PCL scaffolds with different fibre orientations. Here, we applied 3D printing technology to prepare three sets of HA/PCL scaffolds with different fibre orientations (0-90, 0-90-135, and 0-90-45) to study the differences in physicochemical properties and to investigate the response effects of MPs and bone marrow mesenchymal stem cells (BMSCs) on scaffolds with different fibre orientations. The results showed that multi-angle staggered fibres affected the overall porosity and compressive strength of the scaffolds. Compared with the other two groups, the 0-90-45 scaffold induced osteogenic differentiation of BMSCs more significantly, while promoting the polarisation of MPs towards the M2 phenotype to form an osteogenic-friendly immune microenvironment. Unexpectedly, the 0-90-45 scaffold significantly upregulated the expression of angiogenic genes (PDGF, VEGF). Therefore, we conclude that the multi-angle interlaced fibres better mimic the physiological structure of cancellous bone, and that the excellent biomimetic properties reflect the best in vitro osteogenic, immunomodulatory and angiogenic effects. In conclusion, this study is a step forward in the exploration of BET scaffolds and provides a very promising bone filling material.

Comprehensive review of 3D printing techniques emphasizing thermal characterization in biomedical prototyping.

The rapid advancement of 3D printing technology has revolutionized biomedical engineering, enabling the creation of complex and personalized prototypes. Thermal properties play a crucial role in the performance and safety of these biomedical devices. Understanding their thermal behavior is essential for ensuring their effectiveness, reliability, and compatibility with the human body. This review article aims to provide a comprehensive overview of the thermal properties of 3D printed biomedical prototypes. It categorizes these prototypes based on thermal characteristics, examines the thermal attributes of various 3D printing materials, explores the thermal considerations for different biomedical devices, and identifies the challenges and future prospects in this dynamic field.

Three-Dimensional Planning for Vascularized Bone Grafts: Implementation and Surgical Application for Complex Bone Reconstruction in the Hand and Forearm

Background/Objectives: Vascularized bone grafts have been successfully established for complex bone defects. The integration of three-dimensional (3D) simulation and printing technology may aid in more precise surgical planning and intraoperative bone shaping. The purpose of the present study was to describe the implementation and surgical application of this innovative technology for bone reconstruction. Methods: This prospective pilot study was conducted between June 2019 and June 2024. For this evaluation, patients who received vascularized bone reconstruction assisted with 3D technology were included. For reconstruction, the free medial femoral condyle (MFC) flap was used as the vascularized bone graft. Patient-specific 3D-printed templates, based on individual 3D simulations according to defect characteristics, were used for surgical planning, including flap elevation, shaping and inset. Results: A total of six patients (five male) with an average age of 39 years (range 19–62 years) and a mean follow-up time of 15 months (range 5–24 months) were analysed. The indications were as follows: avascular necrosis of the carpal bones, a metacarpal defect after tumor resection and pseudoarthrosis after a fractured ulna. Three patients received an osteochondral and three patients received a cortico-cancellous MFC flap. Conclusions: Our evaluation of clinical application revealed enhanced preoperative planning as well as intraoperative performance. Although the implementation for this technology is challenging, the new insights gained in planning and surgical guidance have led us to incorporate this technology into our standard routine.