1. Your partner in 3D metal printing
Biomedical applications
using METAL ADDITIVE MANUFACTURING
Ruben Wauthle, MSc
Chicago, June 11, 2014
Technical Seminar: Additive Manufacturing
3. Introduction
LayerWise
founded in 2008
spin-off from Leuven University, BE
privately held
profitable since 2012
70+ employees
more than 13 years
experience in metal AM
worldwide presence
large production facilities
highly skilled staff
8. AM metals & specifications
stainless steels
316L 1.4404
17-4 1.4542
15-5 1.4540
titanium and titanium alloys
Ti commercially pure grade 1
Ti commercially pure grade 2
Ti6Al4V grade 5
Ti6Al4V ELI grade 23
NiTi (nitinol)
cobalt chromium alloys
CoCrMo ASTM F75
CoCrMoW
other
Ta (tantalum)
9. AM metals & specifications
AM specifications
Specification LayerWise expertise
Maximum Dimensions 275x275x420mm
Part Accuracy ±0.1% with minimum of ±50µm
Minimum Wall Thickness 200µm
Minimum Feature Size 120µm
Minimum Channel Diameter 250µm
Surface roughness
As manufactured: 4-7µm Ra
High polish: < 0.8µm Ra
12. Standard implants
patient benefits:
new implant designs: better implant performance
uncovered applications
metal AM benefits
design freedom: integration of porous structures
‘complexity for free’
reduced stock levels: multi-size batches
short lead time: no CNC programming
material consumption: no scrap material
13. Standard implants
attention points
cost
certification
validation
quality control
1
2
3
4
5 LayerWise productivity
LayerWise expertise
productivity is key
ISO 9001 & ISO 13485 approved
serial manufacturing of
CE marked and FDA cleared implants
validated processes & materials
process monitoring
18. Patient-specific implants
case 1: world’s first 3D printed full jaw implant
benefits:
perfect fit
restoration of aesthetics
recovery of vital functions
short operation time (4h)
short hospitalization (2d)
HA coating
screw holes for dental prosthesis
Customer: ,NL
Material: Ti6Al4V ELI
19. Patient-specific implants
case 2: triflange acetabular hip implant
benefits:
perfect fit
porous structures – no need for bone grafting
screw positioning
short lead time
Customer: , BE
Material: Ti6Al4V ELI
20. Patient-specific implants
case 3: facial reconstruction
benefits:
high accuracy
anatomical reconstruction
Customer: PDR, UK
Material: Ti6Al4V ELI
24. Porous biomaterials
why AM?
implants with solid & porous parts in one step
regular structures (not random):
full control over geometrical properties
full control over mechanical properties
simulation of mechanical properties (FEA and analytical)
high repeatability
different materials possible
36. Conclusions
LayerWise
metal AM specialists
certified processes and validated technology
serial manufacturing of CE marked and FDA cleared implants
metal AM
fast production
new implant designs
standard and patient-specific implants
integrated porous bone replacement structures
37. Your partner in 3D metal printing
Ruben Wauthle, MSc
Senior Project Manager
+32 16 94 64 20
ruben.wauthle@layerwise.com
38. References
New opportunities for using tantalum for implants with additive manufacturing
European Cells and Materials Vol. 26. Suppl. 1, 2013 (page 15), Abstracts of [MEET THE EXPERT –
IMPLANTS] Materials – Surfaces – Manufacturing, 22-23 April 2013, Interlaken
R. Wauthle, J.-P. Kruth, ML. Montero, L. Thijs, J. Van Humbeeck
Mechanical properties of open-cell metallic biomaterials manufactured using additive manufacturing
Materials & Design, Volume 49, August 2013, Pages 957-965
G. Campoli, M.S. Borleffs, S. Amin Yavari, R. Wauthle, H. Weinans, A.A. Zadpoor
Fatigue behavior of porous biomaterials manufactured using selective laser melting
Materials Science and Engineering: C, Volume 33, Issue 8, 1 December 2013, Pages 4849-4858
S. Amin Yavari, R. Wauthle, J. van der Stok, A.C. Riemslag, M. Janssen, M. Mulier, J.P. Kruth, J. Schrooten,
H. Weinans, A.A. Zadpoor
Crystal structure and nanotopographical features on the surface of heat-treated and anodized porous
titanium biomaterials produced using selective laser melting
Applied Surface Science, Volume 290, 30 January 2014, Pages 287-294
S. Amin Yavari, R. Wauthle, A.J. Böttger, J. Schrooten, H. Weinans, A. A. Zadpoor
39. References
Mechanical behavior of regular open-cell porous biomaterials made of diamond lattice unit cells
Journal of the Mechanical Behavior of Biomedical Materials, Volume 34, June 2014, Pages 106-115
S.M. Ahmadi, G. Campoli, S. Amin Yavari, B. Sajadi, R. Wauthle, J. Schrooten, H. Weinans, A.A. Zadpoor
Effects of bio-functionalizing surface treatments on the mechanical behavior of open porous titanium
biomaterials
Journal of the Mechanical Behavior of Biomedical Materials, Volume 36, August 2014, Pages 109-119
S. Amin Yavari, S.M. Ahmadi, J. van der Stok, R. Wauthle, A.C. Riemslag, M. Janssen, J. Schrooten, H.
Weinans, A.A. Zadpoor
Bone regeneration performance of surface-treated porous titanium
Biomaterials, Volume 35, Issue 24, August 2014, Pages 6172-6181
S. Amin Yavari, J. van der Stok, Y.C. Chai, R. Wauthle, Z. Tahmasebi Birgani, P. Habibovic, M. Mulier, J.
Schrooten, H. Weinans, A.A. Zadpoor
Mechanical analysis of a rodent segmental bone defect model: the effects of surgical variability and
implant stiffness on load transfer
Journal of Biomechanics, In Press, Accepted Manuscript
S. Amin Yavari, J. van der Stok, S.M. Ahmadi, R. Wauthle, J. Schrooten, H. Weinans, A.A. Zadpoor
