AKUH to make 3D-printed PEEK implants

Pakistan’s Drug Regulatory Authority (DRAP) has granted Aga Khan University Hospital (AKUH) permission to produce custom 3D-printed PEEK implants, advancing the hospital as the first in Pakistan to locally manufacture these specialised implants.

This approval enables AKUH to address complex bone reconstruction needs in patients, particularly for facial and skull fractures, through tailored, biocompatible implants.

Aga Khan University Hospital’s neurosurgery chief Dr Shehzad Shamim described implants as external materials created specifically for integration into the human body, often essential when a patient’s bone is fractured or damaged.

“PEEK implants allow us to customise for the patient’s exact bone structure and needs,” Shamim said, explaining that the hospital can now create accurate replacements for critical areas, including the skull, forehead, and facial bones, affected by trauma or cancer.

The PEEK material, formally known as Polyether Ether Ketone, is a biocompatible, lightweight plastic that closely mimics human bone properties. Unlike metal implants, which often shrink or cause discomfort over time, PEEK is more durable and integrates seamlessly with human tissue.

The advanced polymer can remain in the body for up to 50 years, providing a longer-lasting solution with a reduced risk of infection, Dr Shamim noted.

Previously, the hospital relied on imported PEEK implants, a process that increased costs and waiting times. Now, with DRAP’s approval, AKUH can produce these implants locally, cutting costs by nearly 50 to 60 percent, according to Salim Sayani, Director of the hospital’s Technology Innovation Support Centre.

Sayani added that with CT scans and 3D printing, surgeons can precisely match the implant to the missing bone’s exact contours, providing seamless facial symmetry and functional recovery for patients.

The new implant technology has already shown promising results. AKUH has conducted 14 successful surgeries using 3D-printed PEEK implants, which include reconstructions for patients suffering from trauma or tumours.

 Seventeen-year-old Umair Ramzan, who sustained skull injuries in a road accident, received a custom PEEK implant and expressed satisfaction with his recovery.

In the future, AKUH aims to expand its use of 3D-printed PEEK implants to load-bearing bones, such as those in the neck and spine, further broadening treatment options for patients requiring complex reconstructive surgeries.