Severe bone defects in hip revision surgery remain one of the biggest challenges in orthopedics. Standard implants often fail to fit the patient’s anatomy, while custom-made solutions take weeks to produce and are costly for hospitals. This results in delayed treatment, longer operations, and a higher risk of complications. This project develops a 3D printed titanium implant that can be shaped by the surgeon during surgery to fit complex bone defects precisely. Its flexible, formable structure allows immediate adaptation to the patient’s anatomy, providing stable reconstruction without long design or manufacturing lead times. The innovation offers the fit of a custom implant with the practicality of an off-the-shelf product, enabling faster surgery, reduced costs, and more personalized care for patients with complex hip defects.