Easing the Secondary Production Process During Design: The design stage is where the smart decisions are made in additive manufacturing — not only on ways to increase clinical outcomes and additive processes, but also to ease post-processing. In these areas, the process can be made efficient and cost-effective. Receive tips and tricks on orientation, supports, stock material and design features. Enhancing Design through Engineering and Manufacturing Collaboration: Unlike conventional methods, additive manufacturing requires design and manufacturing teams to work closely together very early in the design phase. In a world where the pace of innovation is nearly vertical, it’s imperative to understand this concept early to make additive manufacturing work for you. This discussion lends a high-level overview of best practices when working with internal or external suppliers, and shows examples of the use of additive manufacturing to create innovative medical device designs.

2. Easing the Secondary Production Process During the Design Stage
Maria Pettersson, Ph.D., Orthopedic Industry Specialist for GE Additive, will explain why the
design stage is where the smart decisions are made in additive manufacturing — not only on
ways to increase clinical outcomes and additive processes, but also to ease post-processing.
In these areas, the process can be made efficient and cost-effective. Dr. Pettersson will offer
tips and tricks on orientation, supports, stock material and design features.

3. Easing the Secondary Production
Process During the Design Stage
Maria Pettersson, Ph.D., Orthopedic Industry Specialist, GE Additive
OMTEC, 13th of June, 2018

5. Not cleared or approved by the FDA.

6. Complex is Easy
Not cleared or approved by the FDA.

7. Part design and build planning

8. Orientation
Not cleared or approved by the FDA.

9. Porous structures

10. Features
Not cleared or approved by the FDA.

11. Supports
Not cleared or approved by the FDA.

12. Involve the whole manufacturing chain

13. Machining
Not cleared or approved by the FDA.

14. Inspection
Not cleared or approved by the FDA.

15. Finishing
Not cleared or approved by the FDA.

16. Batch handling
Not cleared or approved by the FDA.

17. Imagination at work

19. This presentation may contain confidential and/or privileged information.
Any unauthorized copying, disclosure or distribution of the material in this document is strictly forbidden.
Enhancing Design Through Engineering &
Manufacturing Collaboration
Laura Gilmour
Global Medical Business Development
OMTEC
Chicago June 12-14

20. EOS | 2
Medical Field: Early Adopters of AM Present:
 Hearing aids
 Dental applications
 Porous acetabular cups
2-5 years:
 Hip & knee replacements
 Other common internal and external medical
devices (e.g. instruments)
> 5-10 years:
 Bioprinting of living tissue for human transplant
 Bioprinting for life sciences R&D
Source: http://www.gartner.com/newsroom/id/3117917 and http://3dprintingindustry.com/2015/08/28/gartner-predicts-medical-3d-printing-to-become-mainstream-in-2-5-years/

21. EOS | 3
50% Expect >10% Increase in Medical AM Applications
SME Medical AM3DP Annual Report, April 2018

22. EOS | 4
FDA Data on Additive Manufactured Medical
Devices
Medical Devices cleared as of Mid-2014a Breakdown by Device Typea
Over 68% falling in the Division of Orthopedic Devices
As of December 2017, over 100 FDA Cleared Additively Manufactured Productsb
Source: aRicles et. al. RAPID May 2014; b“FDA Makes Statement Concerning the Future of 3D Printing in Medicine”, 3D Printing Industry, December 5, 2017

23. EOS | 5

24. EOS | 6
Silo Experience
R&D
R&D
MD
KOLKOL
PD
PM

25. EOS | 7
Silo Experience
R&D
R&D
MD
KOLKOL
PD
PM
Metallurgy
Innovative Shapes
Exposure
and Process
Post-
Treatments
Manufacturing
© Stefan Bindl
Machining
Supports &
Orientation
Design for
Additive Manufacturing
is about…

26. EOS | 8
Important to Establish Whole Process Chain
Source: EOS, Instrumentaria
Digital Design
 CT/MRI based design
 Optimization of part
design
 Use of design software
to generate e.g. lattice
structures
Data processing
Optimization with regard to
 Part orientation
 Placement
 Usage of build area
 Support structures
 Layout
Build process
 Identification of critical
parameters for
application goal
 Parameter optimization
 Material characteristics
Post processing
 Heat treatment
 Post-machining
 Polishing
 Cleaning
DESIGN BUILD FINISH

27. EOS | 9
Important to Establish Whole Process Chain
Source: EOS, Instrumentaria
Digital Design
 CT/MRI based design
 Optimization of part
design
 Use of design software
to generate e.g. lattice
structures
Data processing
Optimization with regard to
 Part orientation
 Placement
 Usage of build area
 Support structures
 Layout
Build process
 Identification of critical
parameters for
application goal
 Parameter optimization
 Material characteristics
Post processing
 Heat treatment
 Post-machining
 Polishing
 Cleaning
DESIGN BUILD FINISH

28. EOS | 10
Leveraging CM Experience in Design Phases for AM

29. EOS | 11
Risks of Implementing AM in Silo Environment
Competitor innovates before you
Redesign needed; adds to launch timeline
CM & OEM expectations not aligned
Device not economically buildable

30. EOS | 12
EOS-Design Process
© EOS GmbH
1
Clarify
Challenge
Create
Concepts
Define
Orientation
Define
Design
Build final
job
Evaluation
Test
job
Test
job
Test
job

31. EOS | 13
Process Application Sprint/Redesign of Application
Clarify challenge
Define main functions
Theoretical Evaluation
Define final orientation
Define redesign
approach for each
function
Final Design
(+ Parameters)
Test for
function 1
No Test for
function 2
Test for
function 3
N-Tests for n-
functions
Evaluation of each test
Yes
Test part building
optional
No
Can a decision be
made for design ?
Test for
design 1
Test for
design 2
Test for
design 3
N-Tests for n-
designs
Post processing
optional
Generate Concepts
Define main goals
Support Structures
+ pre processing
Evaluation of each test
Can a decision be
made for orientation ?
Yes
Using methodic
product development and design
Evaluation

32. EOS | 14
Process Application Sprint/Redesign of Application
Clarify challenge
Define main functions
Theoretical Evaluation
Define final orientation
Define redesign
approach for each
function
Final Design
(+ Parameters)
Test for
function 1
No Test for
function 2
Test for
function 3
N-Tests for n-
functions
Evaluation of each test
Yes
Test part building
optional
No
Can a decision be
made for design ?
Test for
design 1
Test for
design 2
Test for
design 3
N-Tests for n-
designs
Post processing
optional
Generate Concepts
Define main goals
Support Structures
+ pre processing
Evaluation of each test
Can a decision be
made for orientation ?
Yes
Using methodic
product development and design
Evaluation

33. EOS | 15
Process Application Sprint/Redesign of Application
Clarify challenge
Define main functions
Theoretical Evaluation
Define final orientation
Define redesign
approach for each
function
Final Design
(+ Parameters)
Test for
function 1
No Test for
function 2
Test for
function 3
N-Tests for n-
functions
Evaluation of each test
Yes
Test part building
optional
No
Can a decision be
made for design ?
Test for
design 1
Test for
design 2
Test for
design 3
N-Tests for n-
designs
Post processing
optional
Generate Concepts
Define main goals
Support Structures
+ pre processing
Evaluation of each test
Can a decision be
made for orientation ?
Yes
Using methodic
product development and design
Evaluation

34. EOS | 16
Process Application Sprint/Redesign of Application
Clarify challenge
Define main functions
Theoretical Evaluation
Define final orientation
Define redesign
approach for each
function
Final Design
(+ Parameters)
Test for
function 1
No Test for
function 2
Test for
function 3
N-Tests for n-
functions
Evaluation of each test
Yes
Test part building
optional
No
Can a decision be
made for design ?
Test for
design 1
Test for
design 2
Test for
design 3
N-Tests for n-
designs
Post processing
optional
Generate Concepts
Define main goals
Support Structures
+ pre processing
Evaluation of each test
Can a decision be
made for orientation ?
Yes
Using methodic
product development and design
Evaluation

35. EOS | 17
Collaboration
“Additive Minds is an applied
engineering consulting team;
designed to help your
organization transform from
prototyping to production with
additive manufacturing.”

36. EOS | 18
Device OEM
Contract
Manufacturer
Successful
Product
Innovation
Affects
Collaboration

37. EOS | 20
Shaping the Future of Manufacturing