Profesionales médicos

Sept. 23, 2025

Custom 3D printed implants offer a low-risk aesthetic solution for people with conditions such as pectus excavatum, which involves a sunken, deformed or asymmetrical chest wall. Many chest wall deformities do not require a functional or medical repair. However, an aesthetic procedure can reduce psychosocial distress by improving self-image and quality of life.

"Before 3D implants, many chest wall deformities went uncorrected unless they caused medical problems such as pulmonary issues," says Sarvam P. TerKonda, M.D., a plastic surgeon at Mayo Clinic in Jacksonville, Florida. "However, most individuals don't realize there is a way to make the chest wall more balanced and symmetrical."

Pectus excavatum, which represents 90% of chest wall deformities, typically presents at birth or shortly after. The condition can be progressive, with the rib cage growing unevenly or with asymmetrical angulation. One side may develop normally, but the other side is smaller or hypoplastic. A 3D implant fills the space, evening out the chest and improving cosmetic appearance.

How 3D implants work for chest wall deformities

Creating a custom 3D printed implant begins with a low-dose chest CT scan. This imaging reduces radiation exposure and effectively identifies the unique characteristics and measurements needed to create a personalized implant.

"The images and measurements help the implant designers create a mirror image of the fully developed side of the chest wall," says Dr. TerKonda. "Scanning the defect helps outline every curve and undulation in the chest wall. Those details are critical for creating an implant that corrects the contour difference between the two sides and is an exact fit for the patient's anatomy."

Chest wall implants are commonly made from silicone or expanded polytetrafluoroethylene (ePTFE) and typically take 6 to 8 weeks to manufacture. Dr. TerKonda prefers to work with ePTFE because it is pliable and integrates with the body's tissues. The integration makes ePTFE implants more difficult to remove but less likely to shift or move around.

The implant fits over the sunken area of the chest wall, either on top of or underneath the pectoralis major muscle. "It depends on the degree and location of the deformity," says Dr. TerKonda. The implant is surgically inserted through an incision along the rib cage in the lower portion of the chest and is sewn to the ribs or surrounding soft tissue. "The implant itself won't move like a chest, but the softness allows the underlying chest to move freely."

Role of precision and advanced expertise in correcting chest wall deformities

Pectus implant surgery requires careful planning and surgical precision to achieve an aesthetically pleasing and functional outcome. Dr. TerKonda says it's critical to understand implant placement and how the skin and muscle will comply.

"The implant needs to be large enough to create visual balance, but you can't ignore how the implant will affect the skin and muscle," says Dr. TerKonda, adding that creating a personalized implant requires close collaboration between the surgeon and the implant designer. "I know that over time, an implant placed on top of the muscle can compress and thin the muscle. I assess these factors and determine whether the patient will have a better outcome with the implant placed on top of the muscle or beneath it."

Placing the implant can be challenging and requires advanced surgical techniques. The surgeon needs to create a pocket that can accommodate the implant but is tight enough to hold it in place.

"Custom pectus implants aren't only about improving the appearance of the chest wall," says Dr. TerKonda. "They must also allow for natural movement. We want people to get back to their regular activity levels and be able to build and tone their muscles. Expert planning and execution help us deliver those outcomes."

For more information

Refer a patient to Mayo Clinic.