J Shanghai Jiaotong Univ Sci

Journal of Shanghai Jiaotong University(Science) >

2026 , Vol. 31 >Issue 3: 707 - 720

DOI: https://doi.org/10.1007/s12204-026-2925-x

Celebrating 30 Years

Application Principles and Technical Strategies of 3D Printing-Based Digital Technologies in Medical–Engineering Interaction for Precision Treatment of Foot and Ankle Surgery

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  • 1. Clinical and Translational Research Center for 3D Printing Technology, Shanghai Ninth People’s Hospital, Shanghai Jiao Tong University School of Medicine, Shanghai 200125, China; 2. Department of Orthopaedic Surgery, Shanghai Ninth People’s Hospital, Shanghai Jiao Tong University School of Medicine, Shanghai 200011, China; 3. Shanghai Key Laboratory of Orthopaedic Implants, Shanghai Ninth People’s Hospital, Shanghai Jiao Tong University School of Medicine, Shanghai 200125, China; 4. Department of Orthopaedic, Taian City Central Hospital, Taian 271000, Shandong, China

Received date: 2025-12-29

  Revised date: 2026-02-25

  Accepted date: 2026-03-25

  Online published: 2026-05-16

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Abstract

To investigate and analyze the application techniques and principles of 3D printing-based medical–engineering interaction for precision surgery of the foot and ankle, we summarized 216 patients treated at the Foot and Ankle Surgery Team of the Department of Orthopaedic Surgery, Shanghai Ninth People’s Hospital, Shanghai Jiao Tong University School of Medicine, between February 2020 and March 2025, who underwent 3D printing-assisted interventions under medical–engineering interaction. Among them, 152 patients underwent pre-operative 3D reconstruction based solely on CT/MRI imaging, 32 patients underwent deformity localization and quantitative measurements performed in the regions of interest based on these reconstruction, and 26 patients received personalized 3D-printed surgical guides for osteotomy, lesion localization, or broken implant removal. Additionally, 3 patients received customized fixation and rehabilitation orthoses, and 3 patients received personalized 3D-printed prostheses. Using 3D reconstruction, deformity localization and quantitative measurements, personalized 3D-printed surgical guides, and personalized 3D-printed prostheses, individualized treatment strategies were formulated for selected foot and ankle patients, accounting for 17.2% of all surgical cases. The doctors’ satisfaction rate with 3D reconstruction was 97.4%, with the deformity localization and quantitative measurements was 100%, with the guide plate was 92.3%, and with the rehabilitation orthoses and 3D-printed prostheses was 100%. When using the talus-targeting lesion guide plate, 87.5% of patients were able to achieve high-precision localization; and the average number of fluoroscopies during surgery was (3.8±0.8) times, consistent with the preoperative plan. Through continuous medical–engineering interactions and learning, digital technologies and precision treatment plans are being increasingly adopted. Medical–engineering interaction and 3D printing have been fully recognized and applied in foot and ankle surgery. They offer unparalleled advantages, especially for complex orthopedic cases and those requiring precise positioning, providing excellent solutions for the minimally invasive and precise treatment of complex foot and ankle diseases.

Cite this article

Guo Yu, Chang Hanwen, Chen Hongyu, Yang Tianxing, Xu Chen, Zhang Henghui, Wang Shijin, Jiang Wenbo, Dai Kerong, Gan Yaokai . Application Principles and Technical Strategies of 3D Printing-Based Digital Technologies in Medical–Engineering Interaction for Precision Treatment of Foot and Ankle Surgery[J]. Journal of Shanghai Jiaotong University(Science), 2026 , 31(3) : 707 -720 . DOI: 10.1007/s12204-026-2925-x

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