Groundbreaking operation replaces the sternum and portions of the ribs with a custom structure designed to function like natural bone
by Emmitt Barry, Worthy News Washington D.C. Bureau Chief
PETAH TIKVA, Israel (Worthy News) – Israeli surgeons have successfully reconstructed the chest wall of a young cancer patient using a fully personalized, 3D-printed implant, marking a medical first for Israel and opening new possibilities for patients facing complex tumor-removal surgery.
The operation was performed at Rabin Medical Center’s Beilinson Hospital after doctors discovered an exceptionally rare cancer spreading across the patient’s sternum, or breastbone. The woman, identified as Hadas and described as being in her twenties, required the removal of nearly the entire front portion of her chest wall, including her sternum and sections of several ribs.
Doctors initially believed the growth was a benign cartilage tumor. Further testing, however, identified it as a BRAF-altered mesenchymal tumor, an extremely rare form of sarcoma that has reportedly appeared in only about 20 documented cases worldwide.
Removing the sternum created a second major challenge. Surgeons not only had to eliminate the cancer but also rebuild the framework protecting the heart and lungs while preserving the movement needed for breathing, coughing, and ordinary physical activity.
Traditional chest-wall reconstruction often uses synthetic mesh, titanium plates, and medical bone cement. In this case, the surgical team instead created a replacement sternum and rib structure based precisely on the patient’s anatomy, using detailed imaging and advanced 3D-printing technology.
The implant was manufactured from PEKK, or polyether ketone ketone, a high-performance carbon fiber-reinforced polymer. Physicians said the material combines strength with a degree of flexibility resembling natural bone, an important quality for a part of the body that moves continuously with every breath. The structure was also designed to allow the patient’s tissue to gradually grow into and integrate with the implant.
“The challenge in these operations is not only removing the tumor completely, but also restoring a stable chest wall that protects the heart and lungs while allowing normal breathing,” said Dr. Yury Peysakhovich, head of thoracic surgery at Beilinson Hospital. He said the custom reconstruction gave the surgical team a level of precision that conventional methods could not provide.
The roughly two-hour operation was carried out through an incision beneath the breasts to reduce visible scarring. Hospital officials said Hadas has since been discharged and is recovering well at home.
Dr. Israel Weiss, head of orthopedic oncology, said the rarity of both the tumor and its location required an entirely individualized solution. The procedure, he said, demonstrated how cooperation between thoracic surgeons, orthopedic oncologists, engineers, and 3D-printing specialists can give patients options that were unavailable only a few years ago.
The breakthrough reflects Israel’s growing role in personalized medicine, where implants and surgical plans are increasingly tailored to the exact anatomy of individual patients. Beilinson Hospital is also preparing a customized 3D-printed pelvic implant for a teenage cancer patient in an effort to remove an aggressive tumor while potentially avoiding amputation.
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