Background: The fabrication of standard-sized orthopedic implants often results in suboptimal anatomical fit, prolonged surgical times, and elevated revision rates. Three-dimensional (3D) bioprinting has emerged as a disruptive platform capable of producing patient-specific implants with precise geometric fidelity, tunable porosity, and enhanced biological integration.
Objective: To evaluate the clinical performance, biomaterial properties, and workflow efficiency of personalized 3D-bioprinted orthopedic implants compared to conventional manufacturing approaches.
Methods: A comparative analysis was conducted across six bioprinting technologies, evaluating resolution, compatible biomaterials, and fabrication constraints. Clinical outcome data from 480 patients over a 60-month follow-up were analysed for osseointegration, implant survival, pain scores, and revision rates.
Results: 3D-printed implants demonstrated an 83.3% improvement in anatomical fit accuracy (0.3 vs. 1.8 mm deviation), a 23.3% increase in osseointegration rate (91.5% vs. 74.2%), and a 59.6% reduction in revision surgery rate compared to conventional implants (p < 0.001).
Conclusion: 3D bioprinting offers transformative clinical advantages for orthopedic implantology. Standardisation of bioink formulations, regulatory alignment, and cost reduction are key prerequisites for broad clinical adoption.