Patient-specific solutions in orthopedics represent a major advancement in surgical care. These personalized approaches use 3D planning (3D anatomical models) and custom implants and guides designed for each individual patient's anatomy.

The benefits are significant: improved surgical precision, reduced operating time, and lower costs.

However, adoption of patient-specific solutions has faced obstacles in the past. Medical device companies have encountered barriers that slow implementation despite recognizing the clinical advantages.

In this article, we have outlined some of the challenges that medtech companies face in adopting patient-specific solutions and how current digital 3D planning solutions can help resolve some of these challenges.

Adoption challenges for personalized solutions in orthopedics

We recently conducted a poll in LinkedIn asking "What's the biggest challenge your team faces when adopting patient-specific solutions in orthopedics?"

Long lead times emerged as the primary concern, capturing 33% of responses. Teams are frustrated with delays that can impact surgical scheduling.

The remaining challenges split evenly at 22% each:

• Integrating existing workflows
• Lack of resources
• High initial costs

While these obstacles have been real roadblocks in the past, the landscape is shifting.

Advanced 3D planning technologies in 2025 offer targeted solutions for each of these specific challenges. These barriers are now becoming more manageable with the right tools and approaches.

3D planning solutions in 2025: Changing the game in orthopedics

The technology landscape has evolved significantly, offering practical solutions to each challenge identified in our poll. Let's explore how modern 3D planning platforms are directly addressing these adoption barriers.

Reduce preoperative planning lead-times

"Artificial intelligence is transforming how we generate 3D anatomical models," explains Michael Phipps, President and Co-founder at Enhatch. “The days of lengthy manual processes are ending. What once required hours of manual segmentation and multiple revisions now happens much faster.”

AI-powered segmentation tools automatically identify anatomical structures from medical imaging. This cuts the traditional back-and-forth between teams. Models are ready faster and surgeries stay on schedule.

Seamless workflow integration

"The best solutions adapt to your existing processes and team structures rather than forcing you to change everything," notes  Phipps. “Modern 3D planning platforms are developed with flexibility in mind, acknowledging that every team works differently.”

These intuitive platforms integrate with your systems, team structures and workflows. You can easily manage multiple products and configurations. Your team can start using patient-specific solutions without disrupting established processes and team structures.

Address resource constraints

"Streamlined 3D planning tools help teams do more with what they have," says Phipps. “Many medtech companies struggle with limited staff and tight budgets. Modern 3D planning solutions tackle this challenge head-on.”

Modern preoperative planning solutions improve seamless collaboration between multiple stakeholders and thus improve the efficiency of the overall preoperative planning process. Automated features help minimize the number of staff required to support the process. 

User-friendly interfaces mean existing team members can quickly learn the system without extensive training. Cloud-based platforms eliminate the need for expensive hardware investments and IT maintenance.

Maximize ROI on initial costs

"When your preoperative planning process becomes more efficient, you can handle more patient-specific cases each month," notes Phipps. “This increased case volume accelerates your return on investment.” 

The initial costs become manageable when spread across more procedures. Teams see faster payback periods and improved financial outcomes.

3D printing advancements: Complementing 3D planning in orthopedics

While improved planning solutions address the preoperative planning challenges of patient-specific care, the manufacturing side has also seen remarkable progress. 3D printing technology in 2025 has become faster, more reliable, and more accessible than ever before.

Enhanced manufacturing capabilities

Modern 3D printing systems offer improved material properties, faster print times, and better surface finishes. Advanced biocompatible materials now provide stronger, more durable implants and surgical guides. Advanced 3D printing capabilities allow for complex structures that better match patient anatomy and surgical requirements.

Real-world examples demonstrate these manufacturing breakthroughs in action. At Salzburg University Hospital, surgeons successfully performed a cranioplasty using a 3D printed PEEK cranial plate with an optimized honeycomb structure that reduced weight by 40% and was produced in just 10 hours.

The 3D printing of the PEEK cranial plate was done by 3D Systems. This case illustrates how 2025's advanced materials and rapid production capabilities are making complex patient-specific procedures more accessible than ever before.

Growing adoption of point-of-care solutions

These technological improvements are also driving increased adoption of  point-of-care 3D printing solutions. Hospitals and surgical centers can now produce 3D anatomical models on-site, eliminating shipping delays and reducing lead times significantly.

‍In-house 3D printing  capabilities also allows surgical teams to respond quickly to urgent cases or make last-minute modifications based on updated imaging or surgical planning requirements.

These manufacturing improvements work hand-in-hand with advanced planning software to create a complete patient-specific workflow. When planning becomes more efficient and printing becomes more reliable, the entire process from scan to surgery becomes streamlined.

“The convergence of advanced 3D planning and improved manufacturing capabilities is creating unprecedented opportunities for patient-specific care," says Phipps. "You no longer have to choose between speed and customization."

The path forward

While patient-specific solutions have traditionally offered many clinical advantages, there have been barriers to adoption in the past. With the rise of cutting-edge 3D planning solutions, we have been able to address these challenges.

AI reduces lead times. Modern 3D planning solutions streamline workflows and ease workflow integration. Efficient processes maximize existing resources and improve cost-effectiveness.

Advancements in 3D printing technology now offer faster production times and improved material properties. The complete workflow from planning to manufacturing has become more efficient.

The question isn't whether patient-specific orthopedics will become standard practice. It's how quickly teams can adopt the right 3D planning solutions to get there.

References

• Clinical added value of 3D printed patient-specific guides in orthopedic surgery (excluding knee arthroplasty): a systematic review. [Visit page]
• Medical 3D Printing Cost-Savings in Orthopedic and Maxillofacial Surgery: Cost Analysis of Operating Room Time Saved with 3D Printed Anatomic Models and Surgical Guides. [Visit page]
• Enhancing Surgical Efficiency and Radiological Outcomes Through Advances in Patient-Specific Instrument Design. [Visit page]
• Establishing 3D Printing at the Point of Care: Basic Principles and Tools for Success. [Visit page]
• 3D printing metal implants in orthopedic surgery: Methods, applications and future prospects. [Visit page]