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CTRI Number  CTRI/2025/11/098200 [Registered on: 28/11/2025] Trial Registered Prospectively
Last Modified On: 28/11/2025
Post Graduate Thesis  No 
Type of Trial  Interventional 
Type of Study   Dentistry 
Study Design  Randomized, Parallel Group Trial 
Public Title of Study   Comparing three types of custom-made skull implants (Titanium, PMMA, PEEK) in patients with head injury to assess recovery and complications after surgery 
Scientific Title of Study   Evaluation of comparative clinical efficacy of digitally fabricated cranial implants made from ultra-high- molecular weight polyethylene and titanium implants in post-traumatic brain injury patients undergoing cranioplasty- A randomized control trial. 
Trial Acronym  NIL 
Secondary IDs if Any  
Secondary ID  Identifier 
NIL  NIL 
 
Details of Principal Investigator or overall Trial Coordinator (multi-center study)  
Name  Dr Akansha Bansod  
Designation  PHD Scholar 
Affiliation  Sharad Pawar Dental College and Hospital, 
Address  Sharad Pawar Dental College and Hospital DMIHER

Wardha
MAHARASHTRA
442001
India 
Phone  7000626186  
Fax    
Email  akanshabansod29@gmail.com  
 
Details of Contact Person
Scientific Query
 
Name  Dr Sweta kale Pisulkar 
Designation  Professor  
Affiliation  Sharad Pawar Dental College and Hospital, 
Address  SHARAD PAWAR DENTAL COLLEGE AND HOSPITAL, DATTA MEGHE INSTITUTE OF HIGHER EDUCATION AND RESEARCH(DU) sawangi meghe wardha


MAHARASHTRA
442001
India 
Phone  7000626186  
Fax    
Email  drsweta15@gmail.com  
 
Details of Contact Person
Public Query
 
Name  Dr Akansha Bansod  
Designation  PHD Scholar 
Affiliation  Sharad Pawar Dental College and Hospital, 
Address  Sharad Pawar Dental College and Hospital

Wardha
MAHARASHTRA
442001
India 
Phone  7000626186  
Fax    
Email  akanshabansod29@gmail.com  
 
Source of Monetary or Material Support  
NIL 
 
Primary Sponsor  
Name  Institutional funding Sharad Pawar Dental College and Hospital DMIHER  
Address  Sharad Pawar Dental College and Hospital,Datta Meghe Institute of Higher Education and Research (DU) Sawangi Meghe Wardha 442001  
Type of Sponsor  Research institution 
 
Details of Secondary Sponsor  
Name  Address 
NIL  NIL 
 
Countries of Recruitment     India  
Sites of Study  
No of Sites = 1  
Name of Principal Investigator  Name of Site  Site Address  Phone/Fax/Email 
Dr Akansha Bansod  Sharad Pawar Dental College and Hospital DMIHER   201 Department of Prosthodontics
Wardha
MAHARASHTRA 
8208726715

akanshabansod29@gmail.com 
 
Details of Ethics Committee  
No of Ethics Committees= 1  
Name of Committee  Approval Status 
Datta Meghe Institute of Higher Education and Research  Approved 
 
Regulatory Clearance Status from DCGI  
Status 
Not Applicable 
 
Health Condition / Problems Studied  
Health Type  Condition 
Patients  (1) ICD-10 Condition: S02||Fracture of skull and facial bones,  
 
Intervention / Comparator Agent  
Type  Name  Details 
Comparator Agent  Cranioplasty with PEEK  This involves repairing skull defects using PEEK, a high-performance thermoplastic polymer known for its exceptional mechanical properties and biocompatibility. PEEK is gaining popularity in neurosurgery due to its lightweight nature, strength, and ability to closely mimic the natural properties of bone.3 months follow up 
Comparator Agent  cranioplasty with PMMA  This involves using a synthetic resin material to reconstruct cranial defects. PMMA, also known as bone cement, has been widely used in cranioplasty due to its affordability, ease of fabrication, and versatility. 
Intervention  cranioplasty with Titanium  This involves the surgical repair or reconstruction of skull defects using titanium as the implant material. These defects can result from trauma, decompressive craniectomy, congenital abnormalities, tumors, or infections. Titanium is one of the most commonly used materials for cranioplasty due to its excellent biocompatibility, strength, and resistance to corrosion. 
 
Inclusion Criteria  
Age From  18.00 Year(s)
Age To  45.00 Year(s)
Gender  Both 
Details  • Patients aged 18 to 45 years who have cranial defect larger than 3 cm in diameter; resulting from traumatic brain injury and require cranioplasty.
• No previous history of infection at the site designated for cranioplasty.
• Patients with stable medical conditions and no contraindications for surgery or the materials used.
• Patients who are willing to participate in the study and provide informed consent.
 
 
ExclusionCriteria 
Details  1 Patients unfit for cranioplasty
2 Patients presenting with infection before cranioplasty
3 Patients with prior cranial surgeries using non-customized implants.
 
 
Method of Generating Random Sequence   Computer generated randomization 
Method of Concealment   On-site computer system 
Blinding/Masking   Participant, Investigator and Outcome Assessor Blinded 
Primary Outcome  
Outcome  TimePoints 
surgical site infection requiring implant removal or revision,

implant exposure or wound breakdown requiring surgical intervention,

clinically significant graft/implant resorption or structural failure necessitating revision surgery. 
3months 
 
Secondary Outcome  
Outcome  TimePoints 
NIL   NIL  
 
Target Sample Size   Total Sample Size="30"
Sample Size from India="30" 
Final Enrollment numbers achieved (Total)= "Applicable only for Completed/Terminated trials"
Final Enrollment numbers achieved (India)="Applicable only for Completed/Terminated trials" 
Phase of Trial   Phase 1/ Phase 2 
Date of First Enrollment (India)   31/12/2026 
Date of Study Completion (India) Applicable only for Completed/Terminated trials 
Date of First Enrollment (Global)  Date Missing 
Date of Study Completion (Global) Applicable only for Completed/Terminated trials 
Estimated Duration of Trial   Years="1"
Months="6"
Days="0" 
Recruitment Status of Trial (Global)   Not Yet Recruiting 
Recruitment Status of Trial (India)  Not Yet Recruiting 
Publication Details   N/A 
Individual Participant Data (IPD) Sharing Statement

Will individual participant data (IPD) be shared publicly (including data dictionaries)?  

Response - YES
  1. What data in particular will be shared?
    Response - All of the individual participant data collected during the trial, after de-identification.

  2. What additional supporting information will be shared?
    Response -  Study Protocol
    Response -  Statistical Analysis Plan
    Response - Informed Consent Form

  3. Who will be able to view these files?
    Response - Researchers whose proposed use of the data has been approved by an independent review committee identified for this purpose.

  4. For what types of analyses will this data be available?
    Response - To achieve aims in the approved proposal.

  5. By what mechanism will data be made available?
    Response (Others) -  on demand

  6. For how long will this data be available start date provided 02-01-1970 and end date provided 02-01-1970?
    Response (Others) -  after completion

  7. Any URL or additional information regarding plan/policy for sharing IPD? 
    Additional Information - NIL
Brief Summary  

INTRODUCTION

The human skull is a unique bony structure that plays an essential role in the distinctive appearance of an individual. It also acts as a protective vault for the central nervous system. However, this sophisticated structure can be disrupted by multiple disease processes, such as trauma and malignancies, which lead to cranial defects. Every year, approximately 69 million individuals worldwide suffer from traumatic head injuries, which represent an enormous economic burden on medical services [1], and the foremost cause of death and disability [2] Skull bone defects can be caused by trauma, infection of the calvarial bone, and craniectomy for cerebral decompression procedures, and can result in cosmetic or functional problems.

This loss of bone compromises the skull’s function as a brain guard and leaves the brain vulnerable to further physical trauma [3]. In addition, the absence of a sizeable calvarial bone results in several physiological and psychological complications. The skull shape contributes significantly to physical appearance (i.e. any defect in this area will result in extreme disfigurement). Pruzinsky illustrated that individuals with major craniofacial abnormalities might experience social withdrawal and develop psychological and emotional distress [4]. Among the other complications of absent cranial bony coverage is the ‘syndrome of trephine’, described in 1939 by Grant and Norcross.6 Patients experience a cluster of symptoms, including headache, insomnia, behavioural changes, vertigo, tinnitus and fatigue [5,6]. The ‘sinking scalp flap syndrome’ has also been used to describe focal motor deficits in patients who undergo craniectomy and have a persistent hemi-cranial defect. It is also known as motor trephine syndrome [7]. Due to the many complications of cranial defects, cranial reconstruction is performed.

Cranioplasty is a critical surgical intervention performed to repair cranial defects following trauma or neurosurgical procedures. Materials utilized for cranial reconstruction include bone, auto/allografts, distinct biomaterials, and osteoinductive growth factors. Several alloplastic materials have recently been suggested for use as replaceable substitutes when there is a skull defect [8]. In trauma cases, natural bone is not always available for reconstruction due to factors like bone loss, severe fractures, or infection. This limitation makes the use of alloplastic materials highly advantageous in cranioplasty. These materials, such as polymethyl methacrylate (PMMA), hydroxyapatite, polyetheretherketone (PEEK), and metallic mesh, offer effective and reliable alternatives for cranial reconstruction [9,10].

Over the last century, non-biological prostheses have become common for bone tissue repair. In early craniofacial surgeries, metals like silver, gold, and titanium were widely used. However, metallic implants face issues such as stress shielding, corrosion, and cytotoxicity from ion release. Additionally, they interfere with imaging techniques, hindering post-operative monitoring. To address these issues, bioceramics like hydroxyapatite (HA) and tri-calcium phosphate (TCP) were explored due to their bioactivity and similarity to bone. However, their brittleness limits their use. Combining bioceramics with other materials and developing polymer-based implants like PEEK and PMMA offers advantages such as biocompatibility, mechanical strength, and radiolucency, facilitating better post-operative imaging.

Moreover, the advent of digital design technologies has greatly simplified the process, allowing for precise, patient-specific implants. Digital tools have reduced the technical sensitivity of the procedure, enabling surgeons to create custom-fitted cranial implants that match the patient’s anatomy with greater accuracy and efficiency. Digital technologies have revolutionized the design and fabrication of cranial implants, offering precision and patient-specific solutions. However, the material used for cranial implants significantly impacts both the clinical and functional outcomes of the procedure. Commonly used materials such as titanium, polymethyl methacrylate (PMMA), and polyetheretherketone (PEEK) each present unique advantages and limitations in terms of biocompatibility, strength, and infection rates. This study aims to investigate the comparative effectiveness of various implant materials used in cranioplasty for patients with post-traumatic brain injury (TBI), specifically examining both clinical results and functional recovery outcomes.          

 

 

LITERATURE REVIEW

Hamböck et al. (2020) conducted a study to evaluate the impact of implant materials and patient age on long-term outcomes following secondary cranioplasty in patients with severe traumatic brain injury. The study, emphasized the significance of implant material and age in determining clinical success, with titanium implants showing superior outcomes. This research addressed a critical gap in understanding the combined influence of patient-specific factors on cranioplasty outcomes.

Kim et al. (2021), in their study examined predictive factors for surgical site infections (SSIs) after cranioplasty, including the use of 3D-printed implants. The study identified critical factors influencing infection rates and provided insights for improving implant design and surgical protocols. The findings highlighted the importance of patient-related factors and surgical techniques in minimizing SSIs and improving postoperative outcomes.

Koller et al. (2020) performed a retrospective descriptive study comparing cranioplasty failure rates between novel 3D-printed calcium phosphate implants and traditional materials. The study revealed higher success rates and reduced complications with the 3D-printed implants, showcasing their potential as a viable alternative for cranial reconstruction. This work underscored the need for advancements in biomaterials and manufacturing techniques to optimize cranioplasty outcomes.

Patra, Kale (Pisulkar), and Iratwar (2021) conducted an observational study on the clinical outcomes of cranioplasty using various prosthetic materials in traumatic brain injury patients. The research analyzed the performance of different materials, emphasizing the role of material properties in postoperative success. The study contributed to the growing body of evidence supporting the importance of personalized material selection in cranioplasty.

Yang et al. (2019) designed a protocol for a multicenter, assessor-blinded, randomized controlled trial to compare titanium mesh and polyetheretherketone (PEEK) cranioplasty. The study aims to evaluate the clinical effectiveness, safety, and patient satisfaction associated with these two commonly used materials. This trial is expected to provide high-quality evidence for material selection in cranioplasty, addressing a significant gap in clinical practice guidelines.

 

         

RESEARCH GAP

Despite advances in digital design for cranial implants, there is limited research on the comparative effectiveness of different materials in terms of both clinical and functional outcomes in post-traumatic brain injury patients. Most studies focus on individual materials without comprehensive head-to-head comparisons or long-term evaluations of functional recovery and complication rates.

 

RESEARCH QUESTION

What are the comparative clinical, functional, and patient-reported outcomes in post-traumatic brain injury patients undergoing cranioplasty using digitally fabricated cranial implants made from different materials such as titanium, PMMA, and PEEK?

How do the clinical, functional, and patient-reported outcomes compare among post-traumatic brain injury patients undergoing cranioplasty with digitally fabricated cranial implants made from titanium, PMMA, and PEEK materials?"

 

HYPOTHESIS –

There will be significant differences in clinical, functional and patient reported outcomes among patients receiving cranial implants made from different materials (titanium, PMMA, and PEEK) in cranioplasty procedures. Specifically, it is hypothesized that at least one material will demonstrate superior outcomes regarding post-operative complications, functional recovery, and overall patient satisfaction. Additionally, the implementation of digitally designed, patient-specific implants is expected to enhance surgical results across all material types.                                                        

 

 

AIM

To compare the clinical, functional and patient reported outcomes of digitally designed cranial implants made from different materials (titanium, PMMA, and PEEK) in cranioplasty for patients with post-traumatic brain injuries.

 

 

 

OBJECTIVES

1.      To assess infection rates, implant failure, and overall clinical success of cranioplasty performed with different implant materials (titanium, PMMA, and PEEK), evaluated postoperatively at 1-, 3-, and 6-months using CT scan imaging.

2.     To evaluate the neurological and functional recovery of patients undergoing cranioplasty with titanium, PMMA, and PEEK implants, employing validated assessment tools; the Glasgow Coma Scale (GCS) and the Functional Independence Measure (FIM) during postoperative assessments at 1, 3, and 6 months.

3.     To examine patient-reported outcomes related to quality of life and satisfaction following cranioplasty, utilizing validated measures; the SF-36 Quality of Life Questionnaire (SFQOL36) at postoperative intervals of 1, 3, and 6 months.

4.     To compare the clinical and functional outcomes of cranioplasty across the three implant materials—titanium, PMMA, and PEEK—during postoperative evaluations at 1, 3, and 6 months.

STUDY TYPE/DESIGN

A randomized controlled trial comparing three different cranial implant materials (titanium, PMMA, and PEEK).

 

 

 

INCLUSION AND EXCLUSION -

 

Inclusion Criteria:

·       Patients aged 18 to 45 years who have cranial defect larger than 3 cm in diameter; resulting from traumatic brain injury and require cranioplasty.  

·       No previous history of infection at the site designated for cranioplasty.

·       Patients with stable medical conditions and no contraindications for surgery or the materials used.

·       Patients who are willing to participate in the study and provide informed consent.

Exclusion Criteria:

·       Patients unfit for cranioplasty

·       Patients presenting with infection before cranioplasty

·       Patients with prior cranial surgeries using non-customized implants.

 

STUDY SITE

The study will be conducted at the Department of Neurosurgery, AVBRH, Sawangi (M) Wardha.

 

SAMPLE SIZE - ­­­­­­­­­­­­­­­

 

STUDY PARTICIPANTS - Participants will include male and female patients who have sustained traumatic brain injuries and require cranioplasty for the repair of cranial defects. Each participant will be randomly assigned to one of three implant material groups (titanium, PMMA, or PEEK).

Polymethylmethacrylate (PMMA Implant )

PEEK implant

Titanium Implant

Study Participants

Randomisation

Conventional Technique

Hybrid Technique

Digital Technique

Study Participants

Randomisation

Conventional Technique

Hybrid Technique

Digital Technique

Study Participants

Randomisation

Conventional Technique

Hybrid Technique

Digital Technique

Study Participants

Randomisation

Conventional Technique

Hybrid Technique

Digital Technique

Study Participants

Randomisation

 

 


MATERIAL WITH STANDARDIZATION-

The materials utilized for the implants will include titanium, PMMA, and PEEK.

 

METHDOLOLOGY WITH JUSTIFICATION-

Each cranioplasty procedure will be performed by experienced neurosurgeons at the Department of Neurosurgery, AVBRH Hospital, Sawangi (M) Wardha. Clinical information will be gathered from patients or their family members after obtaining written informed consent. Ethical approval for the study will be obtained from the Institutional Ethics Committee prior to its commencement.

·       Preoperative Assessment: Thin-slice computed tomography (CT) scans and 3-dimensional cranial reconstructions will be performed for each patient with skull defects to gather detailed anatomical data.

·       Implant Fabrication: Customized cranial implants made of titanium (Ti), PEEK, or PMMA will be manufactured by specialized company based on the radiographic data obtained from the preoperative scans.

·       Implant Placement: Once the implant is placed at the surgical site, it will be secured to the peripheral calvarial bone using either a PEEK connector or titanium screws. A subcutaneous drain with negative-pressure suction will be placed for two days post-surgery to manage fluid accumulation and aid in the healing process.

I.                Evaluation of clinical outcome:

Clinical outcomes will be assessed by monitoring postoperative parameters; wound healing, infection rate, implant stability, and complications (e.g., implant rejection or resorption). Evaluation will be done by physical examination and CT scan imaging to ensure implant integration and stability. The data will be collected during follow-up visits at 1-, 3-, and 6-months post-surgery for patients in all three groups.

II.              Evaluation of functional outcome:

Functional outcomes will be assessed using neurological scales; the Glasgow Outcome Scale (GOS), and the Functional Independence Measure (FIM), to evaluate cognitive, motor, and overall functional recovery. Baseline preoperative data will be collected and compared with postoperative results at 1, 3, and 6 months to analyse improvements in functional status and recovery in patients undergoing cranioplasty for all three groups.

III.            Evaluation of patient reported outcome:

Patient-reported outcomes will be assessed using the validated SF-36 (Short Form Health Survey) questionnaire to evaluate quality of life, comfort, and aesthetic satisfaction with the cranial implant. Surveys will be conducted preoperatively as a baseline and at 1, 3, and 6 months postoperatively to measure improvements in patient-perceived outcomes.

IV.            Comparison of clinical, functional and patient reported outcome for different materials:

To objectively assess the three materials used in the study, comparative analysis will be made using clinical case data and postoperative follow-up information collected at 1, 3, and 6 months.

 

 

FLOWCHART

 

 

 

 

 

 

 

 

 

 

 

 

 

 

KNOWLEDGE GENERATION (IN ANTICIPATION)-

This study will generate new insights into the comparative clinical performance and functional outcomes associated with different cranial implant materials. The findings could guide surgeons in choosing the optimal material for cranioplasty in post-traumatic brain injury patients, improving long-term outcomes and patient satisfaction.

 

TRANSLATORY COMPONENT (CONCEPTUALIZED)

The findings of this study have the potential to significantly influence future guidelines for material selection in cranioplasty by systematically comparing the clinical and functional outcomes of titanium, PMMA, and PEEK implants. This research aims to provide robust evidence to guide clinicians in choosing the most effective materials for individual patients, ensuring that treatment decisions are informed by solid clinical data. Furthermore, the study could encourage the adoption of advanced, patient-specific cranial implants tailored to each patient’s unique anatomy, optimizing surgical outcomes through customized solutions.

Additionally, the insights gained from this research may facilitate collaborations with medical device manufacturers to refine digital design technologies and integrate cutting-edge manufacturing processes into clinical practice. This could lead to the creation of more effective and easily producible implants, while also developing comprehensive patient-specific treatment protocols that consider individual anatomy and injury severity. Ultimately, the translational component of this study aims to bridge the gap between research and clinical practice, enhancing the standard of care in neurosurgery and improving long-term patient outcomes.


 
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