Precision-built implants for complex orthopaedic cases
Through our Integrated Custom Orthopaedic Solutions (ICOS), JRI combines over five decades of engineering excellence with advanced design capabilities to create precision-made implants designed to address the most challenging cases—where standard implants fall short.
Our range of bespoke custom orthopaedic solutions
Custom orthopaedic solutions that put patient care first
Better fit, better function
Every patient’s anatomy - and orthopaedic journey - is unique. Standard implants aren’t designed for complex or unusual cases. Through our Integrated Custom Orthopaedic Solutions (ICOS), we create precision-engineered, patient-specific implants designed to match the individual patient's needs.
Dedicated end-to-end service
ICOS is more than an implant; it’s a fully managed custom solution. From initial case analysis and advanced design through to manufacture and delivery, our experienced engineering team works in close collaboration with surgeons at every stage. By combining clinical insight with over 50 years of specialist manufacturing expertise, we deliver tailored implants and instrumentation that support predictable outcomes — even in the most demanding primary and revision procedures.
Made for people, built for complexity
For patients affected by significant bone loss, trauma, deformity, or tumour-related defects, ICOS provides surgeons with a dependable solution for truly individual cases. Using advanced Direct Metal Laser Sintering (DMLS) technology, we achieve exceptional accuracy and design freedom - enabling complex geometries and optimised fixation features that traditional manufacturing methods cannot match.
Create, review and collaborate
Seamless custom case management, all in one secure online portal.
How it works
Our team will work with you to connect you to the right solution for your needs.
Analysis
Every case begins with a detailed analysis of the patient’s CT scan. Using advanced imaging software, we generate an accurate 3D anatomical model to fully understand the defect, bone quality and patient requirements.
Design
Surgeon and ICOS Engineer agree on the best possible custom solution for the individual, backed by the surgeon’s (clinical) and engineer’s (mechanical) expertise. Production
Production
Following approval, the implant is produced using Direct Metal Laser Sintering (DMLS), then machined, inspected, cleaned and sterilised to meet strict quality standards.
Delivery
Around 6-8 weeks after design approval, the implant, custom instruments and surgical guides are delivered to the operating facility, ready for surgery.
Our custom orthopaedic solutions in action
Quick-fire answers
Can’t find the answer to your question? Contact our team of experts for a chat!
How long does the custom implant manufacture process take?
From design approval to implant delivery, the full ICOS process typically takes 6–8 weeks. This timeframe includes manufacturing, finishing, inspection and sterilisation — ensuring the implant arrives fully prepared for surgery.
What types of patients benefit most from ICOS?
ICOS custom implants are designed for complex cases where standard solutions may not provide adequate fit, stability or long-term function. Patients who may benefit include those with:
- Severe pain and functional limitation caused by osteoarthritis, traumatic arthritis, rheumatoid arthritis, or congenital hip dysplasia
- Avascular necrosis of the femoral head
- Acute traumatic fractures of the femoral head or neck
- Failed previous surgery, including reconstruction, internal fixation, arthrodesis, hemi-arthroplasty, resurfacing, or total hip replacement
- Increased risk of instability or dislocation
- Complex clinical scenarios where conventional implants or standard treatment approaches may be unsuitable or insufficient
In these challenging situations, ICOS provides a patient-specific solution tailored to individual anatomy and surgical requirements.
What makes the ICOS manufacturing process different?
ICOS uses Direct Metal Laser Sintering (DMLS), which is a state-of-the-art 3D printing technology. Unlike traditional manufacturing, DMLS allows us to build implants layer by layer for extreme precision and detail – this is especially useful in recreating intricate bone structures.
Where are they manufactured?
ICOS custom implants are manufactured in the UK at our dedicated production facility operated by JRI Orthopaedics.
Design, additive manufacture using Direct Metal Laser Sintering (DMLS), precision machining, quality inspection and sterilisation are all managed within our controlled environment — ensuring full traceability, rigorous quality standards and reliable turnaround times.
Can you create new custom solutions?
We offer three dedicated custom ICOS solutions, designed for complex and highly individual cases (Glenoid, Acetabular & Femoral solutions)
If you require an alternative configuration or a different type of implant, our team can work with you to develop a tailored solution. We also supply a range of high-quality off-the-shelf products where a standard option is appropriate.
Please get in touch to discuss your specific requirements — we’re here to support you.
Speak to an orthopaedic specialist today
