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This paper aims to present a systematic review of the latest scientific literature, in the context of pediatric orthopedics, on the development by additive manufacturing of anatomical models, orthoses, surgical guides and prostheses and their clinical applications.

Following the current guidelines for systematic reviews, three databases (Elsevier Scopus^®, Clarivate Web of Science^TM and USA National Library of Medicine PubMed^®) were screened using a representative query to find pertinent documents within the timeframe 2016–2023. Among the information, collected across the reviewed documents, the work focused on the 3D printing workflow involving acquisition, elaboration and fabrication stages.

Following the inclusion and exclusion criteria, the authors found 20 studies that fitted the defined criteria. The reviewed studies mostly highlighted the positive impact of additive manufacturing in pediatric orthopedic surgery, particularly in orthotic applications where lightweight, ventilated and cost-effective 3D-printed devices demonstrate efficacy comparable to traditional methods, but also underlined the limitations such as printing errors and high printing times. Among the reviewed studies, material extrusion was the most chosen 3D printing technology to manufacture the typical device, particularly with acrylonitrile butadiene styrene.

To the best of the authors’ knowledge, this is the first systematic review which annotates, from a more engineering point of view, the latest literature on the admittance of the clinical application of additive manufacturing (and its effects) within typical pediatric orthopedic treatments workflows.

Arthroscopic osteochondroplasty is a minimally invasive procedure that has been used to treat femoroacetabular impingement syndrome, leading to significant improvements in patients’ clinical outcomes and quality of life. However, some studies suggest that inadequate bone resection can substantially alter hip biomechanics. These modifications may generate different contact profiles and higher contact forces, increasing the risk of developing premature joint degeneration. To improve control over bone resection and biomechanical outcomes during arthroscopic osteochondroplasty surgery, this study aims to present a novel system for measuring femoroacetabular contact forces.

Following a structured design process for the development of medical devices, the steps required for its production using additive manufacturing with material extrusion and easily accessible sensors are described. The system comprises two main devices, one for measuring femoroacetabular contact forces and the other for quantifying the force applied by the assistant surgeon during lower limb manipulation. The hip device was designed for use within an arthroscopic environment, eliminating the need for additional portals.

To evaluate its performance, the system was first tested in a laboratory setup and later under in-service conditions. The 3D printing parameters were tuned to ensure the watertighness of the device and sustain the intraoperative fluid pressures. The final prototype allowed for the controlled measurement of the hip contact forces in real-time.

Using additive manufacturing and readily available sensors, the present work presents the first device to quantify joint contact forces during arthroscopic surgeries, serving as an additional tool to support the surgeon’s decision-making process regarding bone resection.