Sirris Medical Ceramic Applications

le centre collectif de l’industrie technologique belge

The collective centre of the Belgian technology industry

Our centre

Federation for the technology industry

Collective centreof the technology industry

• Nonprofit organisation

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• Nonprofit organisation• Industry owned

“Increase the competitiveness of companies of the Agoria sectors through technological innovations”

Mission

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

Our technological sectors

Aerospace Automotive Construction products

Contracting & Maintenance Electrical engineering

Industrial automation Mechatronical engineering

Information and communication technologies (ICT)

Metals & materials Metal processing Mounting & cranes

Plastics & composites Security & defence

Local presence, near the companies

LeuvenMechatronics

Technology Coaching

HasseltBrussels

GhentMaterials Engineering

HasseltMaterials EngineeringProduction Technology

CharleroiAdditive ManufacturingBio-Manufacturing Platform

BrusselsSoftware Engineering & ICTTechnology Coaching

LiègeAdditive ManufacturingMaterials Engineering

Nanomaterials

Additive Manufacturing Process

• Basic data :

Scan / 3D CAD files – STL

• Pre-treatment :

STL corrections, orientation, supports, 2D slicing

3D CAD File

3D STL File

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STL corrections, orientation, supports, 2D slicing

• Manufacturing :

Full automatic

• Post-treatment :

Cleaning, sand blasting, coating, finishing

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Σ 2D layers

Sliced File

Rapid Prototyping

• Stereolithography

• Bi-material 3D Printing

• 3D Printing of wax

• Selective Laser Sintering

• 3D Printing of polymers / plaster

Rapid Prototyping vs Additive Manufacturing

Additive Manufacturing

• Electron Beam Melting

• Selective Laser Melting

• Laser Cladding

• Hybrids of Stereolithography

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• 3D Printing of polymers / plaster

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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |

Functionalparts

Final parts

Visual parts

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)

Sirris ADD capacities & competencies

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• 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)

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• Evolution of medical imagery technology

=> Easy access to 3D world !

Need for custom implants !

Benefits of Additive Manufacturing @ Medical field

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Need of flexibility, complex structures and fast

response for surgery! Very small or even

standard (large) manufacturing series possible

Every human is different (anatomy)

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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

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

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[Sirris ADD]

[Sirris ADD][Sirris ADD]

Medical Additive Manufacturing Software:

ADD capacities & competencies

• Materialise: Mimics• Materialise: 3-matic• 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]

Indirect Manufacturing: Optoform process

le centre collectif de l’industrie technologique belge

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Optoform

Generalities:

• Commercially not available any more• Flexible technology (hybrid SLA):

•Development of very different materials• Possible materials:

•Soft, hard, metallic and ceramic• ISO 13485 certified @ Sirris

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Fabrication steps:

• Preparation and fabrication of the bulk material• CAO / CAD File processing• Automated process manufacturing• Cleaning and recycling of the non-used material• Debinding & Sintering process

[Sirris ADD]

Optoform

Features:

• Layer thickness: 20 - 200µm• Argon laser 400-800mWatt at 351nm and 365nm• Max. Size: 250-350-500mm• Several building plates with variable sizes well suited to small parts and expensive materials• Supports needed


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Material Requirements:

• Composition :Resin+ Fillers (20% to 70% Vol.) + Photo-initiator + Wetting agent + rheological/ thixotropic Agent

• Consistency : Firmness of a toothpaste (Bingham’s model)• Good Lifetime : the filler should not deposit sediment• No UV absorption by the filler ↔ Layer thickness• Support removal & cleaning: not always easy (isopropanol, water,…)

Optoform


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[Sirris ADD] [Sirris ADD]

Materials:

• Alumina• Alumina with 8% of nano Zirconia• Hydroxyapatite• α & β Tri-calciumphosphate• Zirconia• SiC• Stainless steel• Titanium

Optoform

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[Sirris ADD]

• Titanium

• Ceramics & metals need a post-process of debinding & sintering


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Optoform & medical field: CASE STUDIES

Ongoing statuts:

• Porous scaffolds in Hydroxyapatite Ca5(PO4)3(OH)• Diameter ~= 10mm• Macro-porosity ~= 0,5mm• Tests various scaffold structures for bone integration• In vivo testing (rabbits & rats)• Field: Spinal implants & Maxillofacial Surgery

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• Field: Spinal implants & Maxillofacial Surgery• Spinal implants (HAP/TCP): 10.000 manufactured so far (November 2011)

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

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0,5mm



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Sirris Additive Manufacturing: Contact

Carsten ENGEL

R&D Biomedical Engineer

Mail: [email protected]

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

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

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

Sirris Medical Ceramic Applications

Health & Medicine

3d printing

optoform amp

case studies

medical field

sirris add

infosirris

sirris 2011

optoform