Israeli Surgeons Implant 3D-Printed Chest Cage in Rare Cancer Case

A Rare Diagnosis

A young woman identified as Hadas walked into Clalit-Beilinson Hospital with a tumor eroding her sternum. What doctors initially thought was a benign cartilage growth turned out to be an exceptionally rare sarcoma, a BRAF-altered mesenchymal tumor with only about 20 reported cases worldwide. The cancer had eaten through the bone at the center of her chest, and removing it meant taking the sternum and portions of the ribs attached to it.

Why 3D Printing

Replacing the sternum is one of the most complex reconstructions in thoracic surgery. The bone anchors the entire chest, and if the replacement is not precise, breathing mechanics and heart-lung protection can both be compromised. Traditional options include synthetic mesh, titanium plates, or bone cement, but none of those match the patient's anatomy exactly.

The surgical team chose a fully customized 3D-printed chest implant made of PEKK, a high-performance carbon fiber-reinforced polymer. PEKK combines strength with flexibility in a way that resembles natural bone, and it allows surrounding tissue to integrate with the implant over time. The implant was designed specifically for Hadas's anatomy.

The Procedure

The operation lasted about two hours. Surgeons removed the diseased bone and inserted the custom implant through a discreet incision beneath the breasts, minimizing visible scarring while restoring the chest structure. Dr. Yury Peysakhovich, Head of Thoracic Surgery, called it a creative solution enabled by 3D printing technology and close collaboration between surgical specialties.

Hadas has since been discharged and is recovering well at home.

A Pattern of Innovation

This is the first time an entire 3D-printed chest cage has been implanted to reconstruct a chest wall in Israel. It adds to a growing list of Israeli medical centers using 3D technology for complex procedures, from personalized implants to laboratory-grown corneas and augmented reality-guided surgery.

For patients with rare conditions, off-the-shelf solutions often do not exist. Custom 3D printing changes that equation. The cost and time required to produce a one-off implant have dropped enough that hospitals can now offer them outside clinical trials. That shift is making previously impossible surgeries routine.