Additive manufacturing for biomedical applications

1. Additive Manufacturing Department (ADD)
Medical
Applications
Carsten ENGEL The Collective Centre of the Belgian Technology Industry
le centre collectif de l’industrie technologique belge

2. Conventional technologies...
[Random Google image]
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3. Rapid prototyping / tooling / manufacturing
Process…
• Basic data :
Scan / 3D CAD files – STL
• Pre- treatment :
STL corrections, orientation, supports, 2D slicing
• Manufacturing :
Full automatic
• Post- treatment :
Cleaning, sand blasting, coating, finishing
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4. 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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5. 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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6. The utility of Rapid Prototyping / Manufacturing in
the medical field
Leading applications:
• Pre-surgical planning:
[Arcam]
• Custom implant manufacture
• Physician to physician communication
• Powerful patient presentation tool [Z. Corp Medical Modeling Solutions]
• Medical student/resident education
• 3D Surface Scanning/Custom Prosthesis Design
[Objet Connex Eden 500]
[Z. Corp Medical Modeling Solutions]
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7. 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
[Objet] [Objet]
[Objet Connex Eden 500]
[Objet]
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8. 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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9. The utility of Rapid Prototyping / Manufacturing 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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10. Medical Field: CASE STUDIES @ SIRRIS
Leading applications:
• Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
[Sirris - ADD] [Sirris - ADD]
[Sirris - ADD] [Sirris - ADD] [Sirris - ADD] [Sirris - ADD]
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11. Medical Field: CASE STUDIES @ SIRRIS
Leading applications:
• Custom Prosthesis Design
• Complex parts manufacturing
[Sirris - ADD] [Sirris - ADD]
[Sirris - ADD]
[Sirris - ADD] [Sirris - ADD]
[Sirris - ADD]
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12. Medical Field: CASE STUDIES
[Sirris - ADD]
[Sirris - ADD]
0,5mm
[Sirris - ADD] [Sirris - ADD] [Sirris - ADD]
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13. Medical Field: CASE STUDIES in the world
[Prof., Dr J. Poukens - UHasselt]
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14. Medical Field: CASE STUDIES in the world
[Walter Reed Army Medical Center, Washington DC, USA ]
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15. Medical Field @ Sirris: Contact
Carsten ENGEL, Biomedical Engineer
Additive Manufacturing Department
E-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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