1. Biomedical applications for Additive Manufacturing
Additive Manufacturing for
Ceramic parts
ESMA – 8th of Novembre 2012
The Collective Centre of the Belgian Technology Industry
le centre collectif de l’industrie technologique belge

2. Sirris AM&RP capacities - competencies
• Laser sintering of polymeric powder (PA,…): P360 – P390
• Objet Connex 500: bi-material
• Electron Beam Melting (Arcam A2)
• Hybrid SLA system (Optoform)
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3. Custom medical implants, a necessity?
Yes, it will work. But ….
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4. 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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5. ADD capacities & competencies
Medical Additive Manufacturing Software:
• Materialise: Mimics
• Materialise: 3matic
• Marcam: Autofab
• Able Software Corp: 3D Doctor
• Medicim: Maxilim
• ProEngineer
• New: Lenexa: Analyze
• New: Brisbane: Anatomics
• (…)
[Mimics & 3-matic - Materialise]
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6. The utility of Rapid Prototyping / Manufacturing in
the medical field
Trends in biocompatible materials used in Rapid Prototyping / Manufacturing:
Metals: Polymers:
• Titanium (Ti6Al4V) • PTFE (Polytetrafluoroethylene)
• Ti-alloys • PMMA (Polymethyl methaacrylate)
• Stainless steel • PE (Polyethylene)
• Shape memory alloys (Ni-Ti) – in research • PEEK
• Noble materials (Gold) • PEKK
• … • … others, too but not implantable
Ceramics:
• Hydroxyapatite (HAP) Others:
• Zirconia • Hydrogels + Human cells
• Tricalcium phosphate (TCP)
• Alumine
• …
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7. The utility of Rapid Prototyping / Manufacturing in
the medical field
Leading applications:
• Pre-surgical planning:
[Arcam & Objet technology]
• Custom implant manufacture
• Physician to physician communication [Z. Corp Medical Modeling Solutions]
• Powerful patient presentation tool
• Medical student/resident education
• 3D Surface Scanning/Custom Prosthesis Design
• Patient-custom surgical guides (cutting & placement)
[Sirris ADD]
[Z. Corp Medical Modeling Solutions]
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8. The utility of Rapid Prototyping / Manufacturing in
the medical field
Leading applications: “No matter how good our 3-D graphics are, there is
nothing like a model in your hands . . .”
• Pre-surgical planning:
• Implant pre-contouring
• Screw trajectory
• Screw selection/location
• Instrument selection
• Technique rehearsal
• Surgical guides testing
[Objet] [Objet]
[Sirris ADD]
[Objet]
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9. The utility of Rapid Prototyping / Manufacturing in
the medical field
Leading applications:
• Pre-surgical planning advantages:
• Significantly reduces O.R. time
• Lowers cost
• Reduces O.R. team fatigue
• Enhances patient outcomes
• Reduces “re-do” procedures
• Minimizes size of incisions [Z. Corp Medical Modeling Solutions]
• Speeds recovery time
• Improves anatomical alignment
• Enables multiple procedure rehearsals
[Case study: The Alfred Hospital, Melbourne, Australia]
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10. Medical Field: Application fields
Leading applications:
• Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
• Custom Prosthesis Design
• Complex parts manufacturing
[Sirris ADD] [Sirris ADD]
[Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD]
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11. Medical Field: CASE STUDIES @ SIRRIS
[Sirris ADD] [Sirris ADD]
0,5mm
[Sirris ADD] [Sirris ADD] [Sirris ADD]
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12. Medical Field: CASE STUDIES in the world
[Walter Reed Army Medical Center, Washington DC, USA ]
[Dr J. Poukens - UHasselt]
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13. Medical Field: CASE STUDIES in the world
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14. World’s first total mandible implant in Titanium
[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]
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15. World’s first total mandible implant in Titanium
Inferior alveolar
Lingual
Hypoglossal
[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]
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16. Towards newly designed implants
[Butscher A., et al., Structural and material approaches to bone tissue engineering in powder-based three-dimensional printing. Acta Biomater (2010)]
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17. Towards newly designed implants
Ti6Al4V: E(GPa) = 110 !
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18. Towards newly designed implants
Case study: Femoral & Total hip implants
• Tomorrow: Custom-fit femoral implants & adapted Young’s modulus
• Patient custom-fit implants
• Better distribution of the stresses
• Reducing stress-shielding
• Reducing micro-motion between bone & sinkage
• Surface roughness for strong fixation
• Hydroxyapatite coating eased up
• Complex biodegradable scaffolds combining HAP & βTCP
+ +
[Sirris - ADD]
[Sirris - ADD]
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19. The future of bio-manufacturing…not so far away!
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20. Additive Manufacturing: Organ printing
[Karolinska Institute in Stockholm ] [Wake Forest University School of Medicine]
[Wake Forest University School of Medicine]
[Wake Forest University School of Medicine]
[Wake Forest University School of Medicine] [University of Manchester - UK]
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21. « Medical Additive Manufacturing & Rapid Prototyping »
« Sirris »
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22. Sirris Additive Manufacturing: Contact
Carsten ENGEL
Biomedical Engineer
Department of Additive Manufacturing
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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