A one-year-old boy who was born with a rare skull condition that put him at risk of a learning disability has received world-first operation.
When Rory Potter was born in April 2025, his parents, Harry and Jo Potter, from Chesterfield, Derbyshire, raised concerns about his head being longer than expected.
Diagnosed with severe sagittal craniosynostosis – a condition where the skull fuses before birth which leads to the skull to be long from front to back but narrow from side to side – shortly after he was born.
The rare condition affects around one in 1,800 to one in 2,000 babies in the UK. If left untreated, it can lead to learning difficulties, sight or hearing loss, breathing problems, and dental problems like missing or crowded teeth, according to the NHS.
Treatment usually involves skull reshaping surgery, which takes place within the first months of life.
But because Rory’s condition was severe, doctors referred him for a new treatment that is less invasive.
open image in galleryOver the last two decades doctors have used stainless steel springs to gradually widen the gap, giving space for the brain to develop and for new bone to grow.
But now experts have developed new “super elastic” springs using a special metal called nitinol, a nickel and titanium alloy, with Rory the first patient to have them fitted.
Professor Owase Jeelani, a consultant neurosurgeon at Gosh who was part of the team who developed the new springs and led the surgery, said: “Traditional stainless-steel springs are very robust, but they don’t always allow us to fine-tune the force on the skull.
“These new nitinol springs give us much greater flexibility and, in some cases, can prevent the need for further surgery.
“This first surgery is important progress for children with craniosynostosis and so far, we have seen fantastic outcomes.”
open image in galleryEach spring is custom-designed to the patient and their “super elastic properties” allow them to adapt more naturally to a child’s growing skull, experts at Great Ormond Street Hospital (Gosh) said.
The springs were developed by experts at Gosh and University College London (UCL).
Using CT scans, the team created a detailed digital model of each child’s skull to predict how they will respond to surgery. They then design bespoke springs to deliver the right level of force.
Once inserted the springs will remain in place for several weeks to months, gradually reshaping the skull before being removed.
The new technology means children can avoid longer and more invasive operations and should see a reduction in blood transfusion rates, experts said.
open image in galleryProfessor Silvia Schievano, who led the team of biomedical engineers at UCL, said: “This has been many years in the making, with thousands of hours of necessary research undertaken.
“It is a very proud moment to see this technology used in a child with such a positive result. It uplifts the importance of engineering research and clinical care coming together to develop new technologies for improved healthcare.”
Rory had the 45-minute operation to fit the springs in September and only needed to stay in hospital for one night before returning to Derbyshire to his brother Oscar, three, and the family dog Ada.
Nine weeks later, they were removed after his skull reached the desired outcome.
His mother Jo, a 36-year-old project manager, said: “Rory is so happy, cheeky and full of energy. You wouldn’t know what he’s been through, he’s just like every little boy and hitting milestones and he will have a great story to tell when he’s older.
“We cannot thank the team enough for the care, compassion and reassurance. Not to mention their dedication to medical science to support and help children thrive.
“Throughout the process, every element was explained so well. We knew what was going to happen and how, we received amazing support from each member of the team.”