Custom PEKK Triflange Implant for Reconstruction of a Post-infectious Acetabular Defect: A Case Report

Background Complex acetabular defects with associated infection as well as multiple revision procedures remain a significant reconstructive challenge due to compromised bone stock, altered anatomy, and increased risk of recurrent infection. Custom triflange implants have been used to restore pelvic stability in severe bone loss; however, conventional metallic constructs may present limitations in previously infected environments, including challenges with imaging assessment and biomechanical load transfer. Patient-specific implants manufactured from Poly Ether Ketone Ketone (PEKK), a high-performance polymer with mechanical properties closer to cortical bone, may offer an alternative reconstructive strategy. Case Presentation We report the case of a patient with a traumatic acetabular defect following multiple prior surgeries complicated by infection. Following radiographic studies and assessment for potential infection a patient-specific PEKK triflange implant was designed using computed tomography–based preoperative planning. The implant was inserted through a direct lateral approach with fixation tailored to remaining host bone to restore the hip center of rotation and pelvic continuity. Results The implant achieved stable fixation with appropriate alignment. Early postoperative imaging confirmed accurate positioning and construct stability. At most recent follow-up of approximately 7 months, the construct remains stable, with no evidence of loosening or recurrent infection. The patient demonstrated satisfactory early clinical recovery without immediate postoperative complications. Conclusion This case demonstrates the feasibility of a custom PEKK triflange implant for reconstruction of severe post-infectious acetabular bone loss. Patient-specific polymer-based implants may represent a viable reconstructive option in complex revision cases in which traditional metallic implants present limitations. Further investigation is warranted to evaluate long-term outcomes and overall clinical applicability.