iCAT 2026 PLENARY SPEAKERS

Patient-specific, additively manufactured acetabular implants are increasingly used for massive acetabular bone loss and pelvic discontinuity. Systematic reviews report that custom components are retained in ~94% of cases at a mean 7-year follow-up, and short- to early mid-term reviews report ~97.7% survivorship at ~23 months; dislocation and periprosthetic joint infection remain the dominant causes of re-revision, while sciatic nerve palsy is reported in approximately 2% of cases. Case: A female patient with severe developmental dysplasia underwent primary total hip arthroplasty 30 years earlier using a high hip centre reconstruction. She presented with progressive hip pain, progresive aditional limb shortening, and radiographic loosening with cranial migration of the acetabular component, with the proximal tip adjacent to the sacral spinal canal, creating an irregular periacetabular bone defect.

Laser-based additive manufacturing processes have long been established in a variety of industrial applications due to their intrinsic geometric freedom and scalability. In recent years, the previous quasi-isothermal paradigm in polymer powder bed fusion (PBF-LB/P), which relies on the intermediate suppression of crystallization processes at temperatures near the melting point, has evolved into one option alongside the variothermal PBF of semi-crystalline polymers. Variothermal processes rely on significantly reduced build chamber temperatures and focus on the intermediate separation of crystallization-induced shrinkage and the macroscopic part geometry. Based on exposure strategy adaptations, we enable the cold processability on industrially available machinery through the implementation of discretized exposure strategies.

Additive manufacturing enables the production of highly complex metal components with unprecedented design freedom, yet the surface condition of as-built parts often remains a major limitation for demanding engineering applications. Typical surface-related issues include high roughness, partially melted or adhered powder particles, staircase effects, oxidation, cracks, porosity and other near-surface defects, all of which may impair aesthetics, dimensional accuracy, corrosion resistance and especially fatigue performance. For this reason, surface post-processing is an essential step in the AM process chain rather than a secondary finishing operation. A wide range of technologies is currently used, including machining, sandblasting, tumbling, abrasive flow machining, shot peening, ultrasonic impact treatment, laser polishing, chemical polishing, electropolishing, dry electrochemical polishing and plasma electrolytic polishing, often in combination to achieve the required surface integrity and functional performance.

Total hip arthroplasty (THA), renowned for its excellent clinical outcomes and significant impact on patients' function and quality of life, has been celebrated in orthopaedic surgery as the “operation of the century.” Modern, well-executed THA achieves approximately 90–95% survivorship at 10 years, with outcomes improving by nearly 5% over the past decade due to advances in surgical technique, implant design, and biomaterials. However, every implant remains susceptible to biological and mechanical failure, and eventual revision is an inherent risk. Revision hip arthroplasty, particularly in cases of severe acetabular bone loss, presents a considerable technical challenge. Complex three-dimensional (3D) defect morphology, distortion of anatomical landmarks, and compromised bone stock require precise restoration of hip biomechanics and secure implant fixation.

Mandible reconstruction is a challenging step in oral cancer surgery, because it has a complex three-dimensional shape and must simultaneously restore facial symmetry, airway support, mastication and speech. The fibula free flap is considered the gold standard for mandible reconstruction because it provides a long segment of dense cortical bone with a reliable vascular pedicle, allows multiple osteotomies to recreate the mandibular contour, and can support dental implants while permitting simultaneous soft-tissue reconstruction. Virtual surgical planning and 3D-printed cutting guides have become important because they improve accuracy of bony alignment, occlusion, and facial symmetry, reduce operative time, and enhance functional outcomes compared to freehand techniques

Western countries are facing significant challenges, including an ageing population and the demand for improved healthcare solutions. In healthcare, each patient has unique needs, yet conventional medical solutions often rely on generalized approaches. Additive manufacturing (AM) has emerged as a promising avenue for crafting personalized healthcare solutions. Advances in medical imaging and image processing now enable the creation of precise 3D models of patient anatomy, which can be leveraged for tailored designs and treatments. This study explores both current and prospective applications of AM in medicine by examining various case examples.

Based on interviews with 13 professional designers utilizing Additive Manufacturing (AM) for end-use product development, this presentation investigates the impact of AM on product design practice, including processes, tools, outcomes, stakeholder relationships, and ethical considerations. Employing thematic analysis and a systematic, iterative methodology informed by constructivist Grounded Theory, the research identifies five principal themes: the integration of digital and analogue design methods, computational and algorithm-driven design, eclectic adoption of virtual design tools, the continued significance of analogue design, closer engagement with stakeholders, and heightened awareness of sustainability. The findings advance theoretical discussions on the evolution of product design by providing empirical evidence of how AM is transforming contemporary practice. Additionally, the study offers actionable insights for practitioners, educators, and organizations seeking to integrate AM into product development workflows and to define the competencies necessary to leverage AM technologies.

In recent years, additive manufacturing (AM), colloquially known as 3D printing, has evolved from a prototyping technology to a significant production method in numerous industries worldwide. Its ability to produce complex geometries with minimal material waste and significantly reduce production times makes it particularly attractive for the defense sector. The specific advantages of AM for this sector include the potential for cost efficiency, accelerated prototype development, adaptability to specific military needs, and strengthened supply chain resilience.