PETACH TIKVAH, Israel โ Surgeons at Clalit Health Services’ Beilinson Hospital have successfully performed Israel’s first complete chest wall reconstruction using a custom-designed 3D-printed sternum implant after removing an exceptionally rare tumor from a young woman, hospital officials announced.
The groundbreaking operation involved replacing the patient’s entire breastbone and portions of several ribs with a personalized implant manufactured using advanced 3D-printing technology. Physicians say the procedure represents a significant advancement in thoracic oncology and reconstructive surgery in Israel.
The patient, identified only as Hadas to protect her privacy, is in her twenties and had been healthy before developing persistent chest pain that gradually worsened over time.
According to Clalit Health Services, the discomfort initially appeared only during physical activity before progressing to pain even while at rest. Although blood tests were normal and physicians observed no external swelling or visible abnormalities, doctors continued investigating the unexplained symptoms.
A computed tomography scan ultimately revealed a destructive tumor eroding the sternum.
An initial biopsy suggested the growth was a benign cartilage tumor. However, after referral to Beilinson Hospital, a multidisciplinary sarcoma team concluded that the lesion’s aggressive behavior warranted treatment as a malignant tumor and recommended complete surgical removal.
Following the operation, pathologists examined the entire tumor and identified it as a BRAF-altered mesenchymal tumor, an exceptionally rare form of sarcoma documented in only about 20 cases worldwide, according to published medical literature.
A Highly Complex Surgical Challenge
Removing the sternum is considered one of the most technically demanding procedures in thoracic surgery because the breastbone serves as the structural anchor of the chest while protecting the heart and lungs.
Its removal requires precise reconstruction to maintain normal breathing mechanics and preserve stability of the chest wall.
“The sternum is essentially the anchor of the entire chest,” said Dr. Yury Peysakhovich, Head of Thoracic Surgery at Clalit-Beilinson Hospital.
“If reconstruction is not precise, both respiratory mechanics and protection of the heart and lungs can be compromised. Every breath, cough, or physical movement places significant stress on this area, making it one of the most complex reconstructions in thoracic surgery.”
In Hadas’ case, surgeons removed not only the diseased sternum but also sections of the ribs connected to it to ensure complete removal of the tumor.
Customized 3D-Printed Solution
Rather than reconstructing the chest using traditional methods such as titanium plates, synthetic mesh or bone cement, the surgical team opted for a fully customized implant manufactured specifically for the patient’s anatomy.
The operation marked the first time surgeons in Israel implanted an entirely personalized 3D-printed chest cage to reconstruct the chest wall.
The implant was produced fromย polyether ketone ketone (PEKK), a high-performance carbon fiber-reinforced polymer widely used in the aerospace industry because of its combination of strength, durability, and lightweight properties.
Dr. Israel Weiss, Head of Orthopedic Oncology at Clalit-Beilinson Hospital, said the material closely mimics the mechanical properties of natural bone while offering enough flexibility to withstand the continuous movement associated with breathing.
According to Weiss, surrounding tissues are also expected to gradually integrate with the implant over time, improving long-term stability.
Precision Planning
Because every patient’s anatomy differs, surgeons designed the implant specifically for Hadas before the operation.
The customized device was engineered to match the exact dimensions of the bone removed during surgery while restoring the structural integrity of the chest wall.
The procedure itself lasted approximately two hours.
Surgeons accessed the chest through a discreet incision beneath the breasts, minimizing visible scarring while improving the cosmetic outcome following recovery.
Hospital officials said the operation proceeded as planned without major complications.
Successful Recovery
After spending several days recovering in hospital, Hadas was discharged home and continues to recover well.
Doctors say the successful outcome demonstrates how advances in personalized medicine and additive manufacturing are expanding treatment options for patients with rare cancers requiring extensive reconstruction.
“Rare cases require creative solutions,” Dr. Peysakhovich said.
“The combination of advanced 3D-printing technology and close collaboration between multiple surgical specialties allowed us to offer this patient a solution that simply wasn’t available only a few years ago.”
Expanding Role of 3D Printing in Medicine
Three-dimensional printing technology is increasingly being incorporated into complex orthopedic, craniofacial and thoracic surgeries worldwide.
Unlike standardized implants, customized devices can be tailored to match each patient’s anatomy with exceptional precision, potentially improving surgical accuracy, recovery and long-term function.
For patients requiring removal of major skeletal structures because of cancer or trauma, personalized implants may reduce complications while restoring mobility and quality of life.
The Beilinson procedure illustrates how these technologies are beginning to transform highly specialized cancer surgery.
Looking Ahead
Although BRAF-altered mesenchymal tumors remain exceptionally uncommon, physicians say the successful operation provides valuable experience for managing similarly complex cases in the future.
Hospital officials believe the procedure demonstrates the growing capabilities of Israeli medicine in combining surgical expertise, advanced imaging, personalized engineering and multidisciplinary collaboration to treat some of the world’s rarest diseases.
For Hadas, whose unexplained chest pain ultimately revealed one of the rarest known forms of sarcoma, the innovative operation has provided both a successful reconstruction and a new opportunity for recovery after an extraordinary medical journey.
