In a historic achievement for Costa Rica’s public healthcare system, the Costa Rican Social Security Fund (CCSS) has successfully performed its first cranial implant using a custom prosthesis designed, developed, and manufactured entirely in-house using advanced 3D printing technology.
The landmark surgery took place at San Juan de Dios Hospital in San José, marking a major leap forward in the institution’s capability to produce personalized medical devices directly within its own facilities.
Key Highlights at a Glance
64% Cost Savings: In-house production dramatically reduces reliance on expensive external suppliers.
7-Day Turnaround: Production time slashed from months of procurement down to just one week.
52 Patients Targeted: Projected to benefit patients across three major regional hospitals by late 2026.
A Two-Year Strategic Investment in Innovation
According to Esteban Vega de la O, Logistics Manager at CCSS, this achievement is the result of a rigorous two-year initiative involving specialized staff training, infrastructure development, and investments in cutting-edge medical technology.
The institutional investment totaled approximately ₡115 million Costa Rican colones, covering:
- Industrial-grade 3D printers and specialized 3D modeling software.
- Advanced medical-grade washing and curing post-processing equipment.
- Infrastructure adaptations to create a dedicated medical manufacturing workspace.
“The manufacturing of a cranial prosthesis using 3D technology is a milestone in social security. It is the first prosthesis developed internally within the institution as part of an integrated research, development, and innovation process.”
— Esteban Vega de la O, Logistics Manager, CCSS
Precision Engineering Meets Patient Care
The process of creating a custom 3D-printed cranial implant is both highly technical and collaborative:
- Medical Imaging: High-resolution CT or MRI scans map the exact anatomical defect of the patient’s skull.
- 3D Design & Prototyping: Specialized software generates a 3D digital model, followed by a physical prototype.
- Surgical Collaboration: Biomedical engineers and neurosurgeons refine the prototype together to guarantee a perfect fit prior to final manufacturing.
Drastic Reduction in Costs and Wait Times
Beyond technical innovation, internal production delivers immediate economic and operational advantages. The first implant—a size-S cranial prosthesis—achieved a 64% cost reduction compared to external commercial contracting.
Furthermore, response times have been drastically compressed. The full workflow, from initial imaging to final production, now takes approximately seven days—a stark contrast to external procurement processes that previously required months. This dramatic increase in speed is expected to help shrink surgical waitlists nationwide.
Restoring Health, Aesthetics, and Brain Protection
Dr. Jorge Badilla Corrales, Chief of Neurosurgery at San Juan de Dios Hospital, emphasized that cranial implants are critical for patients who have lost sections of skull bone due to severe trauma, brain tumors, or vascular diseases.
“This type of surgery changes a patient’s life. The prosthesis serves three vital purposes: reducing neurological symptoms, restoring aesthetic contour and emotional well-being, and, crucially, protecting the brain.”
— Dr. Jorge Badilla Corrales, Chief of Neurosurgery
Looking Ahead: Scaling Impact Across Costa Rica
The CCSS estimates that by the second half of 2026, at least 52 patients will benefit from this technology across three major medical centers:
- San Juan de Dios Hospital: ~20 patients
- Hospital México: ~30 patients
- Hospital Monseñor Sanabria: ~2 patients
With active development underway to expand 3D printing into spinal implants and other custom medical devices, CCSS Executive President Mónica Taylor reaffirmed that patient-centered care remains the core priority: “We want research and innovation to have a very clear purpose: to improve care and transform lives.”
