Humerus Non-union with Segmental Bone Loss Treated with 3D-printed Prosthesis: A Case Report

Introduction: Non-union of the humeral shaft with segmental bone loss is a challenging clinical problem, especially in elderly patients, where conventional reconstruction with cortical fibular graft carries significant donor site morbidity. The advent of 3D printing technology offers novel solutions for patient-specific reconstruction. Case Report: We report the case of a 70-year-old female with atrophic non-union of the right humeral shaft and 13.68 cm segmental bone loss, 6 years after locking compression plate fixation. Clinically, she had painless abnormal mobility at the fracture site and restricted shoulder motion, without signs of infection. Imaging revealed extensive osteolysis and bone loss. A patient-specific intercalary humerus prosthesis was designed using 3D printing technology. The prosthesis featured a porous lattice structure to facilitate osteointegration and was secured with a customized titanium plate and locking screws for optimal stability. Reconstruction achieved stable fixation with restoration of alignment. The patient had improved limb stability and function with early mobilization. Conclusion: Custom 3D-printed intercalary humerus prosthesis can be a viable alternative to traditional bone grafting in selected cases of humeral shaft non-union with extensive segmental bone loss, offering stable fixation, early functional recovery, and reduced morbidity.