Sirris Medical Ceramic Applications

The collective centre of the Belgian technology industry

le centre collectif de l’industrie technologique belge

Our centre

Federation Collective centre
for the technology industry of the technology industry
• Nonprofit organisation
• Industry owned

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

© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 06/12/2011 2
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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

Ghent Leuven
Materials Engineering Mechatronics
Technology Coaching

Brussels Hasselt
Software Engineering & ICT Materials Engineering
Technology Coaching Production Technology

Liège
Charleroi Additive Manufacturing
Additive Manufacturing Materials Engineering
Bio-Manufacturing Platform Nanomaterials

Additive Manufacturing Process

3D CAD File

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

• Pre-treatment : 3D STL File
STL corrections, orientation, supports, 2D slicing

• Manufacturing :
Full automatic

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

Σ 2D layers

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Rapid Prototyping vs Additive Manufacturing

Rapid Prototyping Additive Manufacturing
• Stereolithography • Electron Beam Melting
• Bi-material 3D Printing • Selective Laser Melting
• 3D Printing of wax • Laser Cladding
• Selective Laser Sintering • Hybrids of Stereolithography
• 3D Printing of polymers / plaster

Functional
parts

Visual Final
parts parts

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Sirris ADD capacities & competencies

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)

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Benefits of Additive Manufacturing @ Medical field

• Evolution of medical imagery technology
=> Easy access to 3D world !

Need for custom implants !
Every human is different (anatomy)

Need of flexibility, complex structures and fast
response for surgery! Very small or even
standard (large) manufacturing series possible

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The utility of Additive Manufacturing technologies
in the medical field

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
[Sirris ADD]

[Sirris ADD]
[Sirris ADD]

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ADD capacities & competencies

Medical Additive Manufacturing Software:

• Materialise: Mimics
• Materialise: 3-matic
• Marcam: Autofab
• Able Software Corp: 3D Doctor
• Medicim: Maxilim
• ProEngineer
• New: Lenexa: Analyze
• New: Brisbane: Anatomics
• (…)

[Mimics & 3-matic - Materialise]

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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

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]

© Sirris | www.sirris.be | info@sirris.be | 06/12/2011 12
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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

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,…)

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Optoform

[Sirris ADD] [Sirris ADD]

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Optoform
Materials:

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

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

[Sirris ADD]


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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
• Spinal implants (HAP/TCP): 10.000 manufactured so far (November 2011)

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

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[Sirris ADD]
[Sirris ADD]

0,5mm

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

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Sirris Additive Manufacturing: Contact

Carsten ENGEL

R&D Biomedical Engineer

Mail: carsten.engel@sirris.be
Mobile: +32 498 91 94 50
Skype: Carsten-Engel

SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be

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Sirris Medical Ceramic Applications

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