​Selective laser melting (SLM) is used to manufacture a patient-specific stainless steel positioning guide for spinal screws. The screws are successfully inserted in the neck vertebrae of a 3-year old patient to strengthen unstable joints. This article highlights the challenges and describes the steps used to design, customise, build and post-process the component.

​Design theories and methodologies are specifically developed to suit AM technologies. This research area focuses on optimising the design process efficiency. For non-experts, the ideation process, as well as the display and analysis of the designs conceptualised, require specific digital assistive tools. This post aims to scope these and summarise their uses.