While for most teenagers, life is all fun and games – revolving around school, friendships, and discovering their passions, for a 15-year-old boy battling a rare jaw tumour, everyday life was a literal struggle. Over six months, a large swelling developed in his lower jaw, making it difficult for him to speak clearly, chew food, and even smile confidently. What started as a worrying medical issue soon became a major emotional and physical challenge for both the teenager and his family.

Doctors later discovered that the swelling was caused by ameloblastoma, a rare but aggressive benign jaw tumour that damages the jawbone if left untreated. Thanks to an innovative 3D-printed titanium jaw implant, surgeons were able to remove the tumour and restore the boy’s ability to eat, speak, and smile again.

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Initially evaluated at a premier institute, the patient's condition was misdiagnosed as an infected cyst via needle biopsy. But according to the doctors, his swelling persisted, destroying his mandibular bone from one angle to the other, leaving teeth "floating" as seen on CT scans. “A 13.8 cm expansile lesion pointed to ameloblastoma, a rare, benign but aggressive tumour. At Manipal Hospital Whitefield, a guided biopsy confirmed it, paving the way for targeted management,” said Dr. Rajashekhar Jaka, Consultant – Surgical Oncology and Robotic Surgery, Manipal Hospital.

“Diagnosing such cases in growing children is tricky, as the bone is still developing up to age 21,” said Dr. Jaka. “We needed accuracy to avoid recurrence, which affects up to 15% of patients,” he added.

Traditionally, reconstruction of the jaw after tumour removal involves using a section of bone from the patient’s leg, known as the fibula free flap procedure. However, doctors believed this option could be risky for the teenager, potentially affecting his growth and complicating future treatments. Instead, surgeons opted for a custom 3D-printed titanium mandible, designed specifically for the patient using CT imaging.

The implant was created in just three days and allowed surgeons to remove the entire diseased portion of the jaw while maintaining facial symmetry, dental alignment, and jaw function. Because the implant eliminated the need for bone harvesting from another part of the body, the surgery was less invasive and significantly faster.

“The surgery was performed on the patient through a hidden neck incision to make it complication-free. The patient had a swift recovery, and he regained his ability to eat, speak, and smile without any visible scars. Cost-effective at one-tenth the price of conventional methods, it suited his socio-economic challenges while offering easy replacement if needed,” said Dr. Jaka.

Doctors say 3D jaw is more cost-effective at one-tenth the price of conventional methods

Experts say this case highlights how 3D printing technology is revolutionizing treatment for complex bone tumours, especially in young patients. Unlike traditional reconstruction methods, customized titanium implants allow surgeons to restore both form and function without sacrificing bone from another part of the body.

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