In September 2023, a workplace accident led to a life-altering injury to an individual and a long journey toward his recovery.

Left with a traumatic brain injury, he underwent a 3D-printed cranial reconstruction at The Medical City in January 2025, a surgical innovation that helped restore the shape of his skull and gave him a renewed sense of normalcy.

The patient was electrocuted while changing a lightbulb, resulting in severe brain trauma.

To relieve pressure caused by internal bleeding, doctors performed an emergency craniectomy, a surgical procedure where a portion of the skull is temporarily removed to allow a swelling brain to expand without being compressed.

While the craniectomy saved his life, it left a section of his skull missing, creating both cosmetic and protective challenges. Years later, the patient returned for cranial reconstruction to restore the skull’s original shape and function.

In the past, doctors used materials like metal plates or bone grafts to repair such defects, but these options sometimes resulted in complications such as infection, heat sensitivity, or discomfort.

At The Medical City, the patient was given a 3D-printed PEEK (polyether–ether–ketone) cranial implant.

It is a custom-made medical device created using advanced imaging and 3D-printing technology. PEEK is a biocompatible, durable plastic that mimics the properties of human bone.

It is lightweight, strong, and does not conduct heat or cold, which makes it more comfortable than traditional metal implants.

Using detailed CT scans of his head, a team of doctors and biomedical engineers designed an implant shaped precisely to match the missing portion of the patient’s skull. This personalized approach allowed for a better fit, minimized surgical risks, and improved healing.

Implant reconstructs skull

The implant used in this case was made and donated by ProtoMed Singapore, a company dedicated to producing patient-specific implants for cranial and maxillofacial applications using 3D printing technology.

William Chia and Aravinda Jayawardhana, both sales and operations directors, and Cindy Tan, finance director, represented ProtoMed in supporting the milestone case.

The surgery, led by Dr. Jerold Justo, along with Dr. John Dy, Dr. Jec Eustaquio and Dr. Michelle Luciano, was a success.

By practicing personalized medicine and looking after the patients’ unique needs, the surgical team was able to significantly reduce operative time, lower risks associated with longer procedures, and promote faster recovery.

He recovered well with no complications and was soon able to return to his home province of Aklan. Today, he has resumed his normal activities and is doing well.

“This technology has made a huge difference in how we do surgeries, reducing operative times and improving the patient’s recovery and ultimately, their quality of life,” Justo said. “It’s exciting to see how we can use innovation to improve and personalize patient care.”

Printed surgery’s future

Looking ahead, Dr. Justo shared that this technology holds promise for broader applications, including patient education, bone reconstruction in orthopedic and ENT (ear, nose and throat) surgeries, and even simulations in complex cases.