Doctors at Nanavati Max Super Speciality Hospital successfully removed a cancerous bone tumour the size of a human heart from the centre of a patient’s chest. After removing the tumour, the surgical team reconstructed the patient’s chest wall using a customised 3D-printed titanium implant designed specifically for her anatomy.
Patient Diagnosis and Medical Evaluation
The patient, a 41-year-old fitness trainer from Mumbai, initially noticed an unusual swelling in the middle of her chest. Concerned about the growth, she underwent imaging tests and a biopsy.
Doctors diagnosed her with grade 2 chondrosarcoma, a form of bone cancer. The tumour had originated in the sternum (breastbone) and had spread to nearby ribs. Because this type of cancer typically does not respond well to chemotherapy or radiation therapy, doctors recommended complete surgical removal as the most effective treatment.
Complex Surgery Led by Multidisciplinary Team
A multidisciplinary team led the surgery to ensure both safe tumour removal and proper chest reconstruction.
The procedure was performed by Dr. Manish Agarwal, Vice Chairman – Orthopaedic Oncosurgery and Lead – Innovations, along with Dr. George Karimundackal, Principal Director – Thoracic Surgery, supported by plastic and reconstructive surgeons.
To eliminate the cancer entirely, the surgical team removed the central sternum and portions of several ribs. Consequently, this created a large defect in the chest wall. Therefore, reconstructing the chest became essential not only to protect the heart and lungs but also to allow the patient to breathe normally and move comfortably.
Custom 3D-Printed Titanium Implant for Reconstruction
Instead of using traditional materials such as mesh and cement, the doctors opted for an advanced solution. They developed a customised 3D-printed titanium implant specifically tailored to the patient’s anatomy.
As per the press release, the implant was designed and manufactured in India using high-precision technology. The entire surgical plan and implant design were created in the hospital’s in-house 3D laboratory, which is routinely used for complex surgical planning and patient-specific implants.
The implant consisted of nine individual components—one piece replaced the breastbone and eight pieces reconstructed the ribs. Surgeons carefully fixed each part to the remaining ribs and breastbone using screws, thereby restoring the natural structure of the chest and enabling normal breathing movements.
Each titanium rib was designed to match the patient’s rib dimensions and included a lattice structure that allows bone tissue to grow into it over time. The implant itself was manufactured by 3D Incredible, a Pune-based company.
Additional Protection and Recovery
After positioning the implant, surgeons covered the reconstructed area with prolene mesh and reinforced it using muscle tissue from both sides of the chest. This approach provided additional stability and protection for the implant.
Following the surgery, the patient demonstrated encouraging signs of recovery. Doctors observed stable breathing and comfortable movement during the initial recovery period.
Doctors Explain the Surgical Challenges
Commenting on the case, Dr. Manish Agarwal said,
“Tumours of the breastbone are rare. In this case, the cancer was located very close to the heart and lungs, which made the removal particularly challenging. However, once the tumour is removed, the bigger challenge lies in rebuilding the chest so the patient can breathe normally while protecting vital organs. The customised 3D-printed implant allowed us to reconstruct the chest almost exactly as it was before. Such reconstructions are extremely rare worldwide, especially with a patient-specific, multi-piece design.”
Dr. George Karimundackal added,
“The breastbone and ribs play a crucial role in breathing. If this area is not reconstructed properly, patients can experience serious breathing difficulties. The design of this implant helped restore both safety and function in a way older techniques often could not.”
Advancing Treatment for Rare Cancers
Overall, this case highlights how advanced surgical technology and collaboration among specialists are enabling doctors to treat rare and complex cancers more effectively. Innovative tools such as 3D-printed, patient-specific implants are increasingly transforming reconstructive surgery and improving patient outcomes.