A research team from the University Institute of Engineering and Technology (UIET) at Maharshi Dayanand University (MDU), Rohtak, has developed a patient-specific jaw implant from poly-ether ether ketone (PEEK) material using a custom-built 3D printer, winning the first prize at the institute’s National Technology Day exhibition.
The project, supervised by Dr Deepak Chhabra, a professor at the Department of Mechanical Engineering, UIET, has drawn wide attention for its potential to transform oral and maxillofacial surgery.
Research scholars Ashish Phogat and Akash Ahlawat designed and developed the custom PEEK 3D printer for the project. The central problem they addressed is a known limitation of titanium — the current standard in oral implants — which, being a rigid metal, can cause secondary damage to surrounding bone and tissue if the patient is re-injured at the same site.
PEEK, a high-performance polymer, absorbs impact the way natural bone does, without transmitting it inward. It is also bio-compatible and can withstand temperatures of up to 500 degrees Celsius, making sterilisation straightforward.
Ashish Phogat explained that building the printer was as important as the material research itself.
“PEEK requires a nozzle temperature above 380°C and a controlled heated chamber — far beyond standard desktop printers. We designed and built the machine from scratch to handle these demands reliably," he said.
Akash Ahlawat added that each implant is derived from the patient’s own MRI scan, converted into a 3D model using Mimic software, making every implant unique to the individual.
“No two implants are alike — that is precisely the point," he said.
M.Tech student Vipin and B.Tech student Harsh also contributed to the project, supporting the mechanical assembly of the printer and assisting with preliminary material testing that helped the senior scholars refine the printing parameters.
Prof Deepak Chhabra noted that the cost is as high as bio-mechanics. Titanium implants are expensive and place reconstructive surgery beyond the reach of many low and middle-income patients.
PEEK, processed in-house, costs far less. “We envision a future where the implant is printed right inside the hospital on the day of surgery," he said.
The team plans to collaborate with maxillofacial surgeons for cadaveric validation before proceeding to clinical trials.
