Sirris materials day 2011 additive manufacturing for biomedical applications - carsten engel - sirris

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

Additive Manufacturing Department (ADD)

Medical Applications

Carsten ENGEL

© sirris 2011 Charleroi | www.sirris.be | [email protected] | 2

Conventional technologies...

CENG05/10/2011

[Random Google image]

© sirris 2011 Charleroi | www.sirris.be | [email protected] | 3

Rapid prototyping / tooling / manufacturing

Process…

• Basic data :Scan / 3D CAD files – STL

• Pre- treatment :STL corrections, orientation, supports, 2D slicing

• Manufacturing :Full automatic

• Post- treatment :Cleaning, sand blasting, coating, finishing

CENG05/10/2011

4

SIRRIS – World leader: Most complete machine park

• 15 engineers and technicians • Two locations: Liège (10 p.) and Charleroi (5 p.)

Rapid Prototyping / Tooling / Manufacturing

• Stereolithography (normal & hi-res)• Paste polymerisation for ceramics and metals (Optoform)• 3D Printing of plaster and metal powder• Laser sintering of polymeric powder (PA,…): P360 – P390• Objet Connex 500: bi-material• Laser sintering of metal powder (parts and mould inserts)• Electron Beam Melting (Arcam A2)• 3D Printing of wax (Thermojet)• Vacuum Casting of Alu, Bronze, Zamak• Laser Cladding (EasyClad) • Selective Laser melting (MTT)

Sirris ADD capacities & competencies

CENG© sirris 2011 Charleroi | www.sirris.be | [email protected] | 05/10/2011

5

Need of flexibility, complex structures and fast

response for surgery! Very small or even

standard (large) manufacturing series possible

• Evolution of medical imagery technology

=> Easy access to 3D world !

Need for custom implants !

Every human is different (anatomy)

Benefits of Additive Manufacturing @ Medical field

CENG© sirris 2011 Charleroi | www.sirris.be | [email protected] | 05/10/2011

05/10/2011 6

The utility of Rapid Prototyping / Manufacturing in the medical field

Leading applications:

• Pre-surgical planning:

• Custom implant manufacture

• Physician to physician communication

• Powerful patient presentation tool

• Medical student/resident education

• 3D Surface Scanning/Custom Prosthesis Design

© sirris 2011 Charleroi | www.sirris.be | [email protected] |CENG

[Z. Corp Medical Modeling Solutions]

[Z. Corp Medical Modeling Solutions]

[Arcam]

[Objet Connex Eden 500]

05/10/2011 7

Leading applications:

• Pre-surgical planning:

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

CENG

[Objet]

[Objet]

[Objet Connex Eden 500]

[Objet]

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

The utility of Rapid Prototyping / Manufacturing in the medical field

© sirris 2011 Charleroi | www.sirris.be | [email protected] |

05/10/2011 8

Leading applications:

• Pre-surgical planning advantages:

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

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

CENG

[Z. Corp Medical Modeling Solutions]

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

The utility of Rapid Prototyping / Manufacturing in the medical field

© sirris 2011 Charleroi | www.sirris.be | [email protected] |

05/10/2011 9

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• Follow up

CENG

The utility of Rapid Prototyping / Manufacturing in the medical field

© sirris 2011 Charleroi | www.sirris.be | [email protected] |

[Sirris - ADD]

[Sirris - ADD]

[Sirris - ADD]

05/10/2011 10

Medical Field: CASE STUDIES @ SIRRIS

Leading applications:

• Physician to physician communication

• Powerful patient presentation tool

• Medical student/resident education

CENG© sirris 2011 Charleroi | www.sirris.be | [email protected] |

[Sirris - ADD][Sirris - ADD]

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

05/10/2011 11

Medical Field: CASE STUDIES @ SIRRIS

Leading applications:

• Custom Prosthesis Design

• Complex parts manufacturing

CENG© sirris 2011 Charleroi | www.sirris.be | [email protected] |

[Sirris - ADD] [Sirris - ADD]

[Sirris - ADD][Sirris - ADD]

[Sirris - ADD]

[Sirris - ADD]

05/10/2011 12

Medical Field: CASE STUDIES

CENG

0,5mm

© sirris 2011 Charleroi | www.sirris.be | [email protected] |

[Sirris - ADD]

[Sirris - ADD]

[Sirris - ADD]

[Sirris - ADD]

[Sirris - ADD]

13

Medical Field: CASE STUDIES in the world

CENG05/10/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |

[Prof., Dr J. Poukens - UHasselt]

14

Medical Field: CASE STUDIES in the world

CENG05/10/2011

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

© sirris 2011 Charleroi | www.sirris.be | [email protected] |

15

Medical Field @ Sirris: Contact

CENG05/10/2011

Carsten ENGEL, Biomedical Engineer

Additive Manufacturing Department

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

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

© sirris 2011 Charleroi | www.sirris.be | [email protected] |