CINCINNATI (June 17, 2025) – An orthopedic surgeon at The Christ Hospital Health Network performed the first-of-its-kind surgery combining a custom 3D printed version of a talus bone with a triple arthrodesis procedure and ankle replacement to treat a patient with advanced ankle joint disease and deformity. The surgery was performed by Robert Kulwin, MD, surgeon at The Christ Hospital.
Previously, patients with advanced ankle conditions like Avascular Necrosis (AVN) of the talus faced limited treatment options, with fusion of the ankle joint and the subtalar joint being the only option. Talus replacement, which preserves motion by replacing the crucial bone in the ankle joint that connects the foot to the lower leg, can lack the stability needed in more severe or structurally complex cases. In the most advanced stages, where traditional techniques are inadequate, amputation may be considered.
“This technology is changing what’s possible,” said Dr. Kulwin. “Traditionally, fusion meant sacrificing movement to relieve pain. But the bone that underwent avascular necrosis was replaced by a cadaver bone which can cause problematic late collapse resulting in poor outcomes. And in this patient fusion really wasn't a good answer for many reasons. By pairing 3D printing technology with traditional surgical methods, we can now offer our patients better outcomes that fit their unique needs while also leading the way in new orthopedic surgical options.”
Prior to the surgery, the patient was unable to walk, put almost no weight on her foot and had to wear a boot. By combining the joint-stabilizing benefits of fusion with a custom 3D-printed talus implant paired to an ankle replacement, Dr. Kulwin restored structure, mobility, and function.
The device, made possible by Stryker and 4Web, is made of cobalt chrome. Post surgery, the patient has said the difference in pain is ‘night and day’ and is now able to walk longer distances without the need for a boot. This custom implant is FDA approved for use in patients with AVN under a humanitarian device exception.
Dr. Kulwin will also be hosting a free webinar on Wednesday, June 25 at Noon. He will discuss how you can address foot and ankle issues and get back to walking, running or simply staying active. In this session you’ll learn, common causes of foot and ankle pain, from tendonitis to arthritis, non-surgical treatments that can improve function and ease pain and when surgery is necessary. If you’d like to register, click here.
About The Christ Hospital Health Network
The Christ Hospital Health Network consists of an acute care hospital located in Mt. Auburn, a remote hospital location in Liberty Township, eight ambulatory outpatient centers and dozens of medical offices throughout the region. For 135 years, The Christ Hospital has provided compassionate care to those it serves. Made up for more than 1,300 physicians and more than 7,200 team members, our mission is to improve the health of our community by providing exceptional outcomes in an affordable way. The Network was recognized by U.S. News & World Report as the #1 hospital in the Cincinnati Region and named to Newsweek’s World’s Best Hospitals list in 2025.