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le centre collectif de l’industrie technologique belge
Additive Manufacturing
for medical applications
Advanced Manufacturing Department (ADM)
Agenda
Sirris - ADD
Additive Manufacturing Process
Benefits of Additive Manufacturing @ Medical field
The utility of Additive Manufacturing technologies in
the medical field
Medical Field: CASE STUDIES @ SIRRIS
Medical Field: CASE STUDIES in the world
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Sirris | Driving industry by technology
130 experts & hight-tech infrastructure
Collective centre of the technology industry • Non profit organization • Industry owned
4,700 industrial interventions (advice, projects, services) •within 1,700 different companies •whose 75% are SME’s •24M EUR turnover
Mission: “Increase the competitiveness of companies of the Agoria sectors through technological innovations”
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Sirris | 24 years of Additive Manufacturing
AM centre – Leading position in EU 16 engineers and technicians 12 high-tech different additive technologies 15 machines in house
Most complete installed base in EU Driving technology companies in applications
Technologies: Nowadays : • Stereolithography (normal & hi-res) • Paste polymerization 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 • Electron Beam Melting (Arcam A2) • Vacuum Casting of Alu, Bronze, Zamak • Laser Cladding (EasyClad) • Laser Beam Melting (MTT) • Bi-material FDM system (MakerBot) • MCOR technology (color 3Dprinter)
Previously : • Laser sintering of metal powder (parts and mould inserts) • 3D Printing of wax (Thermojet) • Fab@home system (for students)
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25/11/2011 5
(…)
Additive Manufacturing Process
25/11/2011 6
• 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
Σ 2D layers
3D CAD File
3D STL
File
Sliced File
Additive Manufacturing Process
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Rapid Prototyping
• Stereolithography
• Fused Deposition Modeling
• Bi-material 3D Printing
• 3D Printing of wax
• 3D Printing of polymers / plaster
• Selective Laser Sintering
Rapid Prototyping vs Additive Manufacturing
Additive Manufacturing
• Electron Beam Melting
• Laser Beam Melting
• Laser Cladding
• Hybrids of Stereolithography
25/11/2011
Functional
parts
Final
parts
Visual
parts
• Specific materials for
each technology
• Some of them are
biocompatible
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Need of flexibility, complex structures and fast
response for surgery! Very small or even
standard (large) manufacturing series possible
• Evolution of medical imagery technology
=> Easy access to 3D world !
Need for custom implants !
Every human is different (anatomy)
Benefits of Additive Manufacturing @ Medical field
25/11/2011
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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]
The utility of Additive Manufacturing technologies
in the medical field
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Medical Additive Manufacturing Software:
The utility of Additive Manufacturing technologies
in the medical field
25/11/2011
• 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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The utility of Additive Manufacturing technologies
in the medical field
Main applications:
• Pre-surgical planning:
• Custom implant manufacture
• Physician to physician communication • Powerful patient presentation tool • Medical student/resident education • 3D Surface Scanning/Custom Prosthesis Design
[Z. Corp Medical Modeling Solutions]
[Z. Corp Medical Modeling Solutions]
[Arcam & Objet technology]
[Objet Connex Eden 500]
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Main applications:
• Pre-surgical planning:
• Implant pre-contouring • Screw trajectory • Screw selection/location • Instrument selection • Technique rehearsal
[Objet]
[Objet]
[Objet Connex Eden 500]
[Objet]
“No matter how good our 3-D graphics are, there is nothing like a model in your hands . . .”
The utility of Additive Manufacturing technologies
in the medical field
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Main applications:
• Pre-surgical planning advantages:
• Significantly reduces operation time
• Lowers cost • Reduces operation team fatigue
• Enhances patient outcomes • Reduces “re-do” procedures • Minimizes size of incisions • Speeds recovery time • Improves anatomical alignment • Enables multiple procedure rehearsals
[Z. Corp Medical Modeling Solutions]
[Case study: The Alfred Hospital, Melbourne, Australia]
The utility of Additive Manufacturing technologies
in the medical field
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Medical Field: CASE STUDIES @ SIRRIS
Main 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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Medical Field: CASE STUDIES @ SIRRIS
Main applications:
• Custom Prosthesis Design • Complex parts manufacturing
[Sirris ADD] [Sirris ADD]
[Sirris ADD] [Sirris ADD]
[Sirris ADD]
[Sirris ADD]
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Medical Field: CASE STUDIES @ SIRRIS
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Femoral & Total hip implants
• Custom-fit femoral implants
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Medical Field: CASE STUDIES @ SIRRIS
Spinal & CMF case studies in HAP/TCP:
• 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)
• Machine: Optoform
• Field: Maxillofacial Surgery in France (Client is confidential)
• Production of 1000 parts / month (total of 10.000/year)
[Sirris ADD]
[Sirris ADD] [Sirris ADD]
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Medical Field: CASE STUDIES @ SIRRIS
Project: “Optobio”
Client: Osseomatrix (Dr Nimal)
• Porous & dense orbital implant in Hydroxyapatite Ca5(PO4)3(OH)
[Sirris ADD] [Sirris ADD]
0,5mm
1,4mm
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Medical Field: CASE STUDIES @ SIRRIS
Project: “Optobio”
Client: Osseomatrix (Dr Nimal)
[Sirris ADD] [Sirris ADD]
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Medical Field: CASE STUDIES @ SIRRIS
Project: Surgical Cutting Template
• CHU Reims (France) • 100% dense Ti6Al4V Titanium • Build time: 6 hours
• Weight: 75g
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Oral and Maxillofacial Plastic Surgery
Project: Surgical Cutting Template • UCL-St Luc (Belgium) • 100% dense Ti6Al4V Titanium
• Build time: 4 hours
• Weight: 25g
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Oral and Maxillofacial Plastic Surgery
[Sirris ADD]
[Sirris ADD]
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Medical Field: CASE STUDIES @ SIRRIS
Demonstration part: Knee implant • 100% dense Ti6Al4V Titanium with porous Ti6Al4V scaffolds • Build time: 8 hours
• Weight: 170g
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Knee implant orthopaedics
Demonstration part: Craniofacial implant • Sirris (Belgium) • Porous Ti6Al4V Titanium scaffold implant
• Polyamide skull on Z-Corp machine
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Cranio-plastic surgery
[Sirris ADD]
[Sirris ADD]
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Medical Field: CASE STUDIES @ SIRRIS
Project: “HEROL” (2002: 4 years)
• Goals:
• Enhance the performances of cranio-maxillofacial
surgery, implant placement accuracy
• Enlarge the fields of applications through AM
technologies
• Processing & editing of 2D CT-Scans
• Decrease operating time
• Simplify complex operations
Example of end-user: A.C.M. Implants (Belgium)
• 3D reconstruction of the hip
• Decision & pre-operation planning for surgeons
• Plaster cast on Z-Corp machine with post finishing
• Collaboration: Sirris; UCL; CERISIC
• Results: creation of spin-off: « CenTIS » (www.centis.be)
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Medical Field: CASE STUDIES @ SIRRIS
Surgical Guide
• Visyos + Centis 3D-Side • Surgical guide for osteotomy • Build time: a few hours depending on geometries
• Weight: < 200g
• Machine: EOS P390 (SLS Polyamide)
• Field: Bone Surgery (bone tumor)
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Medical Field: CASE STUDIES @ SIRRIS
Project: “Nanoker” (2005: 4 years) large scaled European
project
• Goals:
• Development of nanomaterials for improved tribological
applications
• Fabrication on the Optoform machine
• Fields of applications : Knee and hip implants, dental
applications
• Results:
• Development of a very reactive Alumina paste containing
8% of Zirconia nano powders
• Partners (25): www.nanoker-society.org
[Sirris ADD]
[Sirris ADD]
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Medical Field: CASE STUDIES @ SIRRIS
Project: “BIOFACT” (2007 - 2013)
• Goals:
• Design, fabrication and establishment of an external feed
prosthesis controlled by neuronal signals (EEG instead of
EMG)
• Creation of the “Biomanufacturing platform” in Charleroi
• Thermodynamic control, calculation and validation of the
EBM process
• Technologies involved: Connex Eden 500, Arcam A2
• Partners: Sirris; CENAERO; UMONS, CETTIC, ULB
• Results: creation of spin-off: « Human Waves » (soon)
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Medical Field: CASE STUDIES in the world
Replacement of Temporomandibular joints
• Reference: Dr. Jules Poukens, Cranio-maxillofacial Surgeon and Lecturer University Hasselt
• Custom fit Titanium implant with surface porosity: allowing tissue ingrowth & stability
• Polyethylene part fixed to the Titanium implant: flat functional surface & providing a centric
relation posititon for the condyle
• Stereolithographic model for validation
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[Dr J. Poukens - UHasselt]
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Medical Field: CASE STUDIES in the world
Replacement of Temporomandibular joints
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[Dr J. Poukens - UHasselt]
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Medical Field: CASE STUDIES in the world
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[Dr J. Poukens - UHasselt]
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Thanks for your attention
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Bruno Verlee
mobile: 049186 91 83
Sirris
Liège Science Park, Rue Bois Saint Jean 12,
4102 Seraing