New 3D technology for knee replacements

DALLAS (KABC) -- In the past 10 years, the number of total knee replacements in the U.S. has doubled and many of those patients are much younger than ever before. Replacement knees typically come off the shelf in different sizes, but they don't always fit right, causing pain and other complications. Now, new technology allows doctors to make replacement knees that are the perfect fit.

A few months ago, retired pipe fitter Don Plum could hardly stand up because his knees ached.

"It was bone on bone and a lot of severe pain," Plum said.

After getting his new "3D knees," he now walks and even runs pain-free.

Plum had knee replacement surgery done on both knees at the same time.

After a CAT scan made a 3D image of his knees, a 3D printer made two new knees that were a precise fit.

Richard Buch, MD, Orthopedic surgeon at the Dallas Limb Restoration Center says the 3D knees offer a lot of advantages over typical replacement knees, which come in several sizes but seldom fit a patient exactly, and can be a source of recurring pain after surgery.

"It matches their anatomy and then the bone you are taking off is less than it was with a standard knee," Dr. Buch said.

Other advantages to the 3D knee include a shorter hospital stay, quicker recovery time, less pain and more movement.

While the technology still needs much more study, many experts see 3D printing taking a much bigger role in all types of joint replacement.

"I think it's technology at its best," Plum said.

Just ask Plum who says thanks to his 3D knees, he can do anything he wants.

3D knee replacement is covered by most insurance companies and projections are that by 2030, 3 to 4 million knee replacement surgeries will be done every year in the United States.