Printing Bones in the Operating Room? Surgeons May Soon Fix Fractures Like Using a Glue Gun

3D printing in medicine is getting closer to something out of science fiction — and now, it’s becoming handheld.

Researchers from Sungkyunkwan University have developed a portable 3D printing device that allows surgeons to print bone implants directly inside the body during surgery. Instead of inserting a pre-made implant or using traditional bone cement, doctors could one day “draw” new bone structure on the spot, sealing fractures and filling irregular gaps as easily as squeezing a glue gun.

At KBD, we’ve seen the growing impact of 3D printing in medical technology, from lab-grown bone scaffolds to patient-specific implants. But this breakthrough is different — it puts the power of bone regeneration directly into a surgeon’s hand.

Source: 3dprintingindustry.com

How the Bone-Printing Device Works

The device is surprisingly simple in concept. Imagine a hot glue gun — now replace the glue with a warm, biodegradable material made from:

• Polycaprolactone (PCL): A safe, FDA-approved polymer already used in medical implants

• Hydroxyapatite (HA): A mineral naturally found in human bone

When heated and extruded, the mixture cools and hardens instantly into a supportive scaffold, holding the damaged bone in place. Over time, the scaffold slowly dissolves as the body replaces it with real bone, making it both a support structure and a healing guide.

Because surgeons can directly apply the material inside the wound, it automatically conforms to the patient’s anatomy — something prefabricated implants often fail to do.

Tested in Rabbits — With Promising Results

The team tested the device on rabbits with large femoral bone defects that would not heal naturally on their own. Some rabbits received the printed scaffold, while others were treated with standard bone cement.

After 12 weeks:

The printed implants integrated well with surrounding bone
New bone formed more densely and in better alignment
Mechanical strength was higher than cement-treated fractures
No abnormal inflammation or tissue rejection occurred

In short — the bones repaired better when printed directly inside the injury.

Strong, Biodegradable — and Antibiotic-Infused

Beyond structural support, the researchers also tested whether the printed bone scaffolds could deliver antibiotics to reduce infection risk — a major concern in orthopedic surgery.

They added gentamicin or vancomycin to the material before printing, and lab tests showed that gentamicin-loaded implants were highly effective at stopping E. coli and Staphylococcus aureus — two of the most common infection-causing bacteria in surgical wounds.

That means one device could help:

Seal the fracture
Support healing
Prevent infection — all in one step

How This Differs From Traditional Implants

Instead of forcing bones to fit implants, this device lets implants fit bones.

What Still Needs Improvement

While the results are exciting, the researchers acknowledge that more development is needed before this technology reaches human operating rooms. Next steps include:

• Better adhesion to wet bone surfaces

• More precise control for complex fractures

• Larger animal trials, followed by regulated human studies

• FDA evaluation for safety and long-term durability

But the trajectory is clear — we’re heading toward a future where surgical tools don’t just repair injuries… they print the solution on demand.

The Bigger Picture: 3D Printing Is Reshaping Medicine

This isn’t the first time we’ve seen 3D printing push the boundaries of regenerative medicine.

• In a Netherlands-based study, researchers used 3D printed polycaprolactone implants to save a patient from lower-leg amputation.

• At UNSW in Australia, scientists developed 3D-printed bone containing living cells that can be printed directly into defects at room temperature.

• Other teams are exploring cartilage, airway, and even heart tissue printing using similar bio-friendly materials.

Each breakthrough brings us closer to a world where hospitals don’t order implants — they print them.

What This Means for Patients

For trauma victims, seniors with osteoporosis, and even soldiers on the battlefield, this kind of portable technology could mean:

Faster surgeries
Better long-term recovery
Fewer follow-up procedures
Less risk of infection and rejection

Instead of depending on standard-sized implants or metal screws, each patient could receive a bone repair structured exactly for their body.

At KBD — We’re Watching These Innovations Closely

While this technology isn’t in hospitals yet, its direction is unmistakable — medicine is becoming more personalized, more automated, and more device-driven.

As legal advocates, we believe innovation must always come with accountability. That means:

• Ensuring patients understand any new surgical materials used in their bodies

• Guaranteeing proper regulatory testing before adoption

• Holding device manufacturers responsible if defects ever cause harm

At KBD, we follow emerging technologies like this so we can be ready — not just to celebrate breakthroughs, but to protect the people who will depend on them.

Our Ongoing Coverage of 3D Printing & Legal Responsibility

At KBD, we’ve been closely tracking how 3D printing intersects with product liability and consumer safety. Here’s a quick recap of our previous coverage on this fast-evolving technology:

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1. Drones & Emerging Tech Risks — A Parallel to 3D Printing

In our Emerging Technology Series, we explored drones as a case study in how new consumer technologies can create unexpected risks. Like 3D printers, drones started as exciting innovations — now they pose real-world safety, privacy, and property threats. Our takeaway:

When cutting-edge technology hits the real world, the law must be ready before people get hurt.

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2. FDA Steps Into 3D Printing — Medical Devices Under Watch

We examined how the FDA is responding to 3D-printed medical devices, issuing guidance on how they should be designed, tested, and regulated. While 3D printing enables customized surgical tools and patient-specific implants, it also creates new failure points with limited clinical history.

As 3D printing expands in healthcare, regulation — and legal accountability — must expand with it.

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3. 3D Printing in Pharmaceuticals — The Rise of Printed Drugs

We covered another milestone when the FDA approved SPRITAM, the first 3D-printed epilepsy medication. This breakthrough illustrated just how deeply additive manufacturing is entering medicine. It also raised a key question:

If a 3D-printed drug fails or causes harm, who is liable — the manufacturer, software provider, or printer?

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4. Who’s Responsible When 3D Printing Goes Wrong?

In our core analysis, there is a  complex chain of responsibility behind 3D-printed products. Whether injuries stem from toxic materials, faulty designs, weak parts, or unsafe printer machinery, victims face a common challenge — who do you actually sue?

Our stance is clear: Innovation is welcome — but never without accountability.
If a company profits from 3D printing technology, it must also answer for the risks.

Future of orthopedic care? A surgeon holding a printer — not a scalpel.

And when that future arrives, we’ll make sure patients have the knowledge and legal protection they deserve.

To read more about 3D Printing innovations read our blogs:

Emerging Technology Series: The FDA Guidance for 3D Printed Medical Devices

Emerging Technology Series: 3D Printed Medical Devices, And Those Who Print Them, Can Face Potential Liability

KBD Presents – Emerging Technology Series: 3D Printing