Complete sternal cleft individualized repair using a 3D-printed polyether ether ketone model: a case report

Bicuspid aortic valve (BAV) is a common anatomical variation that the aortic valve possesses two functional cusps. Sternal cleft is a rare congenital malformation which is caused by failed fusion of sternal bones. Early surgical repair is advised; otherwise, alternative surgical techniques should be performed. Due to their biocompatibility and elasticity, 3D-printed polyether ether ketone (PEEK) implants can be used. Complete sternal cleft coexistence with BAV is infrequent.

A 49-year-old man with a 6-month history of paroxysmal shortness of breath and exertional chest tightness presented to our hospital. The man was diagnosed with BAV with severe aortic valve regurgitation and a complete sternal cleft. He underwent aortic valve replacement surgery using the bovine pericardial aortic valve. Concurrently, a 3D-printed PEEK implant surgery was performed to address the sternal cleft. The patient’s postoperative recovery was uneventful.

In this case, 3D-printed PEEK implants were used for high biocompatibility and elastic modulus. However, because PEEK material inherently lacks biological activity, enhancing this aspect remains a focal point of clinical research.