Tibiotalocalcaneal Arthrodesis Using Custom 3D Printed PEKK Implant for Treatment of Talar AVN

Historically custom implants have been made from metal, bulk allograft, and PEEK, among others. PEKK has seen increased utilization in medicine, specifically in custom implants due to its higher tensile strength and also its molecular composition that aids in promoting cellular activity, such as bone healing. In this case report, we present a 72-year-old female who initially presented with a collapse of her talus after failed attempted ankle arthrodesis. A custom PEKK talus implant was designed, implanted and secured via tibiotalocalcaneal arthrodesis using an intramedullary nail. The patient had significant improvement in AOFAS (17 to 92), FFI (90 to 8), and VAS (9 to 0) from preoperative evaluation to the final 1.5-year postoperative follow-up. This is one of the only case reports that documents the utilization of a custom PEKK implant for lower extremity reconstruction. Although more studies are needed, this case report shows promising results with PEKK implants, especially in limb salvage procedures. Level of Clinical Evidence: 5, Case Report.