confidential
Bodycote 5eme Seminar
Dépôts de couches minces pour applications
médicales
confidential2
Medical Coatings Key Site Map
Olten CH
ISO13485Le Mee FR
ISO 13485
Consett UK
ISO 13485
USA-NJ
Rockaway
ISO 13485
Wuxi, China
ISO 9001
(ISO 13485)Chassieu
France
ISO 13485
Cleveland OH
2015, ISO 13485
Guanzhou, China
ISO 9001
(ISO 13485)
Taegu, Korea
ISO 9001
(ISO 13485)Portland OR
2015 ISO 13485
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Ionbond – Coating Equipment Technologies (vacuum technology)
PVD
Physical Vapor Deposition
CVD
Chemical Vapor Deposition
PACVD
Plasma Activated Chemical Vapor Deposition
Ionbond – Equipment Coating Portfolio
Deposition from 100°C to
500°C
Coating thickness
depends on exposure to
coating source
Deposition >800°C
Uniform coating thickness
Stimulation of diffusion
between different
materials
Deposition 150-200°C
Coating thickness
depends on the space to
generate plasma
confidential
Coating Equipment Technologies
Physical Vapor Deposition (PVD)
Arc evaporation
Magnetron sputtering and HIPIMS
4
Chemical Vapor Deposition
(CVD)
Plasma Activated CVD
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Coatings for Medical Application
5
Medthin™ biocompatible coatings for implants, tools and instruments
Certified coatings for medical applications
Medthin™ biocompatible coatings
Wear and friction reduction
Ion barrier coatings for implants
Color coding and glare reduction for
instruments
Improved edge retention for cleaner cut
Cell attachement
ISO 13485
confidential
Product and Services Overview
6
Other Services
A comprehensive portfolio of coating services and coating equipment
Equipment
CVD
Coating Services
Cutting
Tools
Forming
Molding
Automotive Deco
Sports
Luxury
MedicalIndustrial
Racing
Aerospace
Tooling Components
CVA
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Ionbond Coatings for the Tool Market
Ionbond™ PVD and Bernex™ CVD coatings improve productivity
7
Complete portfolio
Hardcut™, Crosscut™, Maximizer™
Ionbond™ 01 TiN, 30 CrN etc.
Bernex™ 10 TiN-TiC-Tin, 29 Al2O3 etc.
Less lubricants and coolants
For longer lasting tools
Ionbond™ 90 Concept, 43 a-C:H
Bernex™ 29 Al2O3 , 32 CrC etc.
Improved product finish
confidential
Coatings for Component Applications
Increased component lifetime, reduced friction, higher output for less input
8
Higher power density for modern engines
Tribobond™ DLC coatings
Engine and fuel injection components
TS 16949
Maximum power output
Tribobond™ DLC and high temperature
resistant coatings
Powertrain, Drivetrain
Custom engineered
confidential
Coatings for Component Applications II
Lower maintenance requirement, higher uptime and less lubrication
9
Higher load and reduced wear
Tribobond™ 46 CrN+a-C:H:W
Bernex™ 32 CrC
Reduced service cost
Tribobond™ 01 TiN, 30 CrN, 40 a-C:H:W
Bernex™ 66 Al
Improved lifetime
Aerospace industry certifications
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Coatings for Decorative Surfaces
Hard and durable decorative coatings preserve the good look for years
10
Scratch and corrision resistant
Decobond™
Interior and exterior goods
Automotive
A new standard in luxury goods
Diamondblack™ ADLC
Watch cases and movement components
Fashion accessories
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Bernex™ CVD and CVA Equipment
Equipment for carbide inserts, forming tools and component coatings
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CVD
Bernex™ BPXpro
Industry standard system
Large coating portfolio
Inserts and forming tools
CVA
Bernex™ ALUVAP
Al diffusion coatings for turbine blades
3D process reaches cooling channels
confidential
Medthin - Thin Film Coatings for Medical
Thin films are: nitrides... Ceramic type of structures
Thickness ranging between 1 to 20 µm.
Biocompatible and possible to use on implants
12
confidential
Biocompatibility Evaluation-Master Files
13
confidential
Reason: 10 to 15 % of patients suffer from an epicutaneous metal allergy
14
Source: Schäfer T et al.,
Epidemiology of contact allergy in
adults, Allergy, 2001.
13,1
2,4
1,1
5,8
1,40,7
20,4
3,4
1,5
0
5
10
15
20
25
Nickel Cobalt Chrome
Popula
tion in %
MenWomen
All Together
60% of revision
are caused by
metal allergy
Why MedthinTM on Implants?
confidential
Symptoms of metal allergies
15
1
5
Eczema after metal implantation Effusion after metal implantation
Source: Thomsen M, Rozak M, Thomas P. Pain in a chromium-allergic patient with total knee arthoplasty: disappearance of
symptoms after revision with a special surface-coated TKA – a case report. Acta Orthopaedica 2011; 82 (3):x-x. Epup ahaed of print
Symptoms of allergic reactions:
pain
eczema
aseptic implant loosening
impaired wound healing
Why MedthinTM on Orthopedic Implants?
confidential
Expectations from Coatings Performance
16
Wear reduction
Ion release reduction from substrate
Leading to longer life time of implants, younger patients to profit
Coatings have a cost which still represent a clear benefit
Avoid potential catastrophic failures of bulk ceramics
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Generation I: PVD Arc Evaporation Coatings for
Implants
State of the art: cathodic arc eveporation, «Random Arc»
17
17
- 25 V - 100 V
SS
N
Substrate
Evaporation
source OFF
Evaporation
source “ON”,
shape I
Coating
Evaporation
source “ON”,
shape II
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TiN as deposited
Ra~0.4µm
5-10 microns coating
thickness
18
TiN after polishing
Ra~0.02µm
Generation I: PVD Arc Coatings for Implants
SEM mapping
of
macroparticles
confidential
-Dental
-Hip
-Knee
-Spine
-Ankles
-Shoulders
-Specials
-Screws
-Eye
Generation I: PVD Arc Coatings for Implants
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Pappas et al; 61st Annual Meeting ORS, Mar ‘94.
Hip Simulator UHMWPE Wear Testing
TiN Coated Femoral Head
9 um TiN coated Ti-6-4
resurfacing cups.
Surface finish = 0.04 um.
Articulating against UHMWPE.
Distilled H2O @ 37oC.
4 station hip simulator.
Load: 0-2200N.
Generation I: PVD Arc Coatings for Implants
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.1
.2
.3
.4
.5
.6
0
CYCLES X1065 10 15 20 25 30 35 40 45 50
0.045
Co-Cr 32mm
TiN 32mm
TiN 47mm
Pappas MJ, Makris G, Buechel FF: Titanium Nitride Ceramic Film Against
Polyethylene A 48 Million Cycle Wear Test.
Clinical Orthopaedics and Related Research 317:64-70, 1995.
HIP SIMULATOR COMPARATIVE WEAR OF
Co-Cr-Mo vs. TiN
Generation I: PVD Arc Coatings for Implants
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Generation I: PVD Arc Coatings for Implants
TiN coating substantially reduces the Co ion release from the substrate
TiN substantially reduces wear of UHMWPE
Implants coated with TiN are in the market since Y1997
Statistically it appears that Generation I coated implants can last longer
than 15years
22
Ion release test:
Inductively coupled plasma mass
spectroscopy (ICP-MS) analysis of
the collected
OrthoPOD test liquids
CoCrMo 0.9 <0.6 0.1
TiN
coated <0.1 <0.6 <0.1
Co Cr Momg/L
Ion Release from CoCrMo
confidential
Ion Release Benchmarking: Generation I
23
J Fischer, X G Hu, J. L. Tipper, T.D. Stewart, S. Williams, M.H. Stone, C. Davies, P. Hatto,
J. Bolton, M. Riley, C. Hardaker, G.H. Isaac, G. Berry and E. Ingham,
Proc Instn Mech Engrs Vol 216 part H J. Enginnering in Medicine
Medthin Coatings against CoCrMo counter part (CoM- Coating against Metal): Over
40% drop of metal ion release from CoCrMo due to barrier formed by Medthin
coatings (against ion release).
Monolayer: MedthinTM 01 TiN, typical
film thickness from 6-10 µm
Monolayers:: MedthinTM30 CrN,
typical film thickness from 3-10 µm
Ion C
oncentr
ation µ
g/l
confidential
Generation II: Steered Arc and Magnetron
Sputtering
Goal: Less coating roughness less coating thickness
Cathodes ON/OFF make multilayers, evap/cooling reduces droplet emission
Steered arc leads to less droplets, less energy density on the target
Hybrid steered arc and magnetron processes
Planar rectangular targets
confidential
Generation II Steered Arc and Magnetron
Sputtering
Coating Structure - denser films
Thinner films, 3-6 µm
Les rough filmes Ra~0.150µm
Less time used for polishing
Multilayers in the market since Y2007
25
confidential
Generation II: Steered Arc and Magnetron
Sputtering
Ion release reduction from metal implants (Co, Cr, Mo, Ni etc) up to 98%
Wear reduction from UHMWPE up to 65%
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98
%
98
%
95
%
90
%Ion C
oncentr
atio
n µ
g/l
0
50
100
150
200
250
300
350
400
450
Mo Ni Co Cr
CoCrMo
Both components coated
AS reference
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Generation III: Pulsed Plasma Technologies
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HiPIMS 1
DC 7
DC 3 HiPIMS 5
Heater
Bias
Pulse
single
Pulse
single
E2E1E1 E2
DC
Powersupply
DC
Powersupply
Pulsed
Plasma
Magnetron
Sputtering
source,
planar
rectangular
Increase energy and produce coating quasi
without droplets, lower roughness
Use of pulse technologies for high energy
pulse plasma , good coating adhesion
confidential
No Evaporation, instead , Ar ions sputter target
materials to form a plasma
Sputter yield depends on the material, e.g. Ti is high
& Nb is lower
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- 500 V
- 100 V
SS
N
Argon (Inert) gas
ions
Coating
substrate
Sputtering
source ON
Generation III Pulsed Plasma Technologies
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PPT – Pulse plasma technologies
Application of short, high energy pulses promotes:
• High ionization of coating flux leading to:
Dense coating structures
Good compound formation
Enhanced coating adhesion
• Allows deposition of non-conductive
materials
Generation III Pulsed Plasma Technologies
confidential
Generation III pulsed plasma technologies
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Keep film thickness 3-7max microns
Eliminate the droplets, avoid
polishing
Ra<0.05µm as deposited
Deposited on multiple geometries
Quite good coating uniformity
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Generation III, MeSiN coating shows a wear track, sort of “run in”
Similar wear of UHMWPE pins compared with generation II
31
Generation III pulsed plasma technologies
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Generation III pulsed plasma technologies
SiNx coatings on CoCrMo reduced the release of metal ions into the solution by two orders of
magnitude.
CoCrMo showed a dissolution rate between 0.7 and 1.2 nm/day,
SiNx coatings showed dissolution rates between 0.2 and1.2 nm/day. Si is not a problem for patients
7um SiN coating lasts for 48 years
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confidential
Polishing Techniques
Slow manual polishing
Much quicker, Drag polishing
sufficient for magnetron PVD,
PACVD and pulsed coatings
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confidential
Examples of Application on Implants
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Generation I
MedthinTM 01
TiN on ASTM
F136 Ti-6Al-
4V . Coating
deposited with
high thickness
Generation II
Medthin
multilayer
PVD on
CoCrMo
Generation III
pulse
technologies
coated knee
component
Medthin 43 ADLC
and its possible
multilayers
PEEK BaSO4 with
top MedthinTM 65
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ADLC coated implants - Application
MedthinTM 43 ADLC used for spinal implants
Sold in 25 different countries
8 years in the market
Implanted over 10’000 discs worldwide
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0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
0.00 1.00 2.00 3.00
depth [µm]
co
nce
ntr
atio
n [
at%
]
H
C
O
Si
Ar
Cr
Fe
W
RBS analysis of the ADLC
coating
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Scanning Electron Micrographs
Showing the coating roughness and morphology
Some heterogeneity (porosity) was noticed at high magnification
36
MedthinTM 65 Ti on PEEK – Morphology
10µm
MedthinTM 65 with 5 µm thickness
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Antireflective Coatings
37
Performance improvements with Medthin™ 20 AlTiN,
Goal: Minimize eye fatigue, provide high contrast
between instruments and tissue
Laser Marking Gold over AlTiN
Medthin™ 20 AlTiN used in high volume
applications, instruments and dental
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65
100
138
180
0
50
100
150
200
a-C:H (ADLC) Cr + a-C:H Cr + a-C:H:W
+ a-C:H
Cr + CrN +
a-C:H
Lo
ad
carr
yin
g c
ap
ab
ilit
y [
%]
.
CrxN/ADLC multilayer for
instruments
Anti Reflection and Low Friction
All New DLC coatings with CrN interfaces
MedthinTM 41 MedthinTM 42MedthinTM 40MedthinTM 43
confidentialFootnote39
MedthinTM 42 CrN/ADLC
DLC coating amourphous
and dense
CrN coating polycrystalline
Dense Structures; High Adhesion
CrN coating if not top
coated with DLC grain
boundaries are a pathway
to the substrate material
and chemical changes
may arise including
corrosion phenomena
confidential
Some Examples MedthinTM for Instruments
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Medthin™ 01
TiN or
Medthin™ 60
ZrN
Medthin™ 20
AlTiN
Medthin™33
CrCN
Medthin™ 40,
41, 42
multilayers DLC
Medthin™ 43
ADLC
Thickness mesured in
the coupons [µm]
2-6 2-6 1-4 2-6 2-3
Adhesion [N] or class
(ISO 26443)
Excellent Excellent Excellent Very Good Average
Color Appearance Gold (TiN), light
gold (ZrN)
Gray-Black Gray-Black Gray-Black Black
Surface preparation
prior to coating
Passivation ok,
Ra<0.5µm ok
Tolerates better surface oxides/ blasting/non conductive surfaces prior to
coating
Passivation ok,
Ra<0.2µm ok
Adhesion suffers
from surface
contaminations
Cleaning and
sterilization after
coating
Resistant/Rob
ust
Should not be
clean with Al
solvent agents
Resistant/Robust to cleaning and all sterilization types and
number of cycles
Corrosion
improvement
compared with non
coated SS
Good Good Very Good, rather
dense coating
Excellent, Good,
confidential
Laser Marking Parameters
41
MedthinTM01 TiN
MedthinTM33 CrCN
MedthinTM20 AlTiN
MedthinTM DLC
Laser marking made at different depths
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Medthin™ Coating Application Areas
42
Dental Instruments – color coding
Dental Implants and Abutments –
reduced wear
Heart Implant – ventricular assist
cardiac pump systems
Spine Implants – cell atachment onto
PEEK material
Spine Implants – cervical disk
applications for wear and metal ion
release reduction
Hip Instrument – intramedullary reamer
improved performance
Hip Implant – hip resurfacing implant head
reduced wear of UHMWPE
Knee Implant – reduced wear and metal
ion release
Knee Implant –improved bone cell
attachment
Ankle Implant – reduced wear and
abrasion
Small Bone Implants – reduced
wear and extended life
confidential
Contacts
43
Dr. Antonio Santana
Head Segment Medical
+41786555916
Or