Plate fit of a novel clavicula plate system (VariAx Clavicle) developed using a CT-based anatomical bone database compared to reconstruction plates individually formed by surgeons

Background: The aim of this study was the comparison of the plate to bone fit of manually bent reconstruction plates with two industrial prebent clavicle midshaft plates (VariAx Clavicle, Stryker, Duisburg, Germany). The precontoured plates were developed using an anatomical 3D computed tomography (CT)-bone database. Methods: From an anatomical database of 334 clavicles 8 were randomly chosen and manufactured from artificial bone as physical 3D models using a rapid prototyping system and three surgeons of various qualification levels performed manual bending. The plate to bone fit of the manually bent plates was then compared to the fit of the VariAx midshaft plates. Results: The industrially manufactured precontoured plates showed a high rate of plate fit with a fit error of less than 1.5 mm² and with a significant difference in comparison to the manually bent plates. Conclusions: The development of osteosynthesis plates using anatomic 3D databases led to a higher degree of plate fit when compared to manually bent plates even for bones with a variable structure, such as the clavicle.