2012 11-08-3 d-printing-event-ceramics-medical

Biomedical applications for Additive Manufacturing

le centre collectif de l’industrie technologique belgeThe Collective Centre of the Belgian Technology Industry

Biomedical applications for Additive Manufacturing

Additive Manufacturing for Ceramic parts

ESMA – 8th of Novembre 2012

Sirris AM&RP capacities - competencies

• Laser sintering of polymeric powder (PA,…): P360 – P390• Objet Connex 500: bi-material

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© sirris 2012 Charleroi | www.sirris.be | [email protected] | 15/11/2012

• Objet Connex 500: bi-material• Electron Beam Melting (Arcam A2)• Hybrid SLA system (Optoform)

Custom medical implants, a necessity?

Yes, it will work. But ….

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Next generation pre-operative manufactured implants:

• Custom implant manufacture :

• CT-Scan• CAD File of the patient is produced• Engineer + Surgeon 3D implant approved• FEM analysis (when needed)• Custom manufacturing (low cost)• Surgery

The utility of Additive Manufacturing technologies

in the medical field

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• Surgery• Follow up

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[Sirris ADD]

[Sirris ADD][Sirris ADD]


Medical Additive Manufacturing Software:

ADD capacities & competencies

• Materialise: Mimics• Materialise: 3matic• Marcam: Autofab• Able Software Corp: 3D Doctor• Medicim: Maxilim

ProEngineer

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• ProEngineer• New: Lenexa: Analyze• New: Brisbane: Anatomics• (…)

[Mimics & 3-matic - Materialise]


The utility of Rapid Prototyping / Manufacturing in

the medical field

Trends in biocompatible materials used in Rapid Prototyping / Manufacturing:

Metals:• Titanium (Ti6Al4V)• Ti-alloys• Stainless steel• Shape memory alloys (Ni-Ti) – in research• Noble materials (Gold)

…

Polymers:• PTFE (Polytetrafluoroethylene)• PMMA (Polymethyl methaacrylate)• PE (Polyethylene)• PEEK• PEKK• … others, too but not implantable

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• Noble materials (Gold)• …

Ceramics:• Hydroxyapatite (HAP)• Zirconia• Tricalcium phosphate (TCP)• Alumine• …

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• … others, too but not implantable

Others:• Hydrogels + Human cells



the medical field

Leading applications:

• Pre-surgical planning:

• Custom implant manufacture[Arcam & Objet technology]

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• Physician to physician communication

• Powerful patient presentation tool

• Medical student/resident education

• 3D Surface Scanning/Custom Prosthesis Design

• Patient-custom surgical guides (cutting & placement)

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[Z. Corp Medical Modeling Solutions]


[Sirris ADD]



• Pre-surgical planning:

• Implant pre-contouring• Screw trajectory• Screw selection/location• Instrument selection• Technique rehearsal• Surgical guides testing

“No matter how good our 3-D graphics are, there isnothing like a model in your hands . . .”


the medical field

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• Surgical guides testing

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[Objet]

[Objet]

[Objet]

[Sirris ADD]



• Pre-surgical planning advantages:

• Significantly reduces O.R. time• Lowers cost• Reduces O.R. team fatigue

• Enhances patient outcomes• Reduces “re-do” procedures


the medical field

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• Reduces “re-do” procedures• Minimizes size of incisions• Speeds recovery time• Improves anatomical alignment• Enables multiple procedure rehearsals

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[Case study: The Alfred Hospital, Melbourne, Australia]


Medical Field: Application fields


• Physician to physician communication• Powerful patient presentation tool• Medical student/resident education• Custom Prosthesis Design• Complex parts manufacturing

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[Sirris ADD]

[Sirris ADD] [Sirris ADD][Sirris ADD]

[Sirris ADD]

[Sirris ADD]


Medical Field: CASE STUDIES @ SIRRIS

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0,5mm

[Sirris ADD] [Sirris ADD] [Sirris ADD]

[Sirris ADD] [Sirris ADD]


Medical Field: CASE STUDIES in the world

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[Dr J. Poukens - UHasselt]

[Walter Reed Army Medical Center, Washington DC, USA ]


Medical Field: CASE STUDIES in the world

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World’s first total mandible implant in Titanium

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[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]


World’s first total mandible implant in Titanium

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[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]

Hypoglossal

Lingual

Inferior alveolar


Towards newly designed implants

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[Butscher A., et al., Structural and material approaches to bone tissue engineering in powder-based three-dimensional printing. Acta Biomater (2010)]



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Ti6Al4V: E(GPa) = 110 !



Case study: Femoral & Total hip implants

• Tomorrow: Custom-fit femoral implants & adapted Young’s modulus

• Patient custom-fit implants• Better distribution of the stresses• Reducing stress-shielding• Reducing micro-motion between bone & sinkage• Surface roughness for strong fixation• Hydroxyapatite coating eased up• Complex biodegradable scaffolds combining HAP & βTCP

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• Complex biodegradable scaffolds combining HAP & βTCP

+ +

[Sirris - ADD]

[Sirris - ADD]


The future of bio-manufacturing…not so far away!

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Additive Manufacturing: Organ printing

[Wake Forest University School of Medicine][Karolinska Institute in Stockholm ][Wake Forest University School of Medicine]

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[Wake Forest University School of Medicine]

[Wake Forest University School of Medicine][Karolinska Institute in Stockholm ][Wake Forest University School of Medicine]

[University of Manchester - UK]

[Wake Forest University School of Medicine]


« Medical Additive Manufacturing & Rapid Prototyping »

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« Medical Additive Manufacturing & Rapid Prototyping »

« Sirris »


Sirris Additive Manufacturing: Contact

Carsten ENGEL

Biomedical EngineerDepartment of Additive Manufacturing

Mail: [email protected]: +32 498 91 94 50Skype: Carsten-Engel

22© sirris 2012 Charleroi | www.sirris.be | [email protected] |

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15/11/2012

Skype: Carsten-Engel

SIRRISRue Auguste Piccard, 20B-6041 GOSSELIES BELGIUMhttp://www.sirris.be

2012 11-08-3 d-printing-event-ceramics-medical

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