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2 n d B i o T i N e t Wo r k s h o p , 2 0 1 2 - 0 3 - 0 6
Your PARTNER in Additive Manufacturing
Dental and surgical applications of Additive Manufacturing: from
research to daily business Dr. Ir . Peter Mercelis
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© LayerWise NV, all rights reserved © LayerWise NV, all rights reserved
Presentation overview
About LayerWise
Introduction to Additive Manufacturing
AM of dental implant prostheses and medical implants
From R&D to business
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© LayerWise NV, all rights reserved © LayerWise NV, all rights reserved
About LayerWise 3
Who We Are LayerWise was incorporated in 2008 as a spin-off from the University of Leuven
Dept. Mechanical Engineering & Dept. Metallurgy and Materials Engineering
Started by Peter Mercelis and Jonas Van Vaerenbergh
Unique focus on Additive Manufacturing of metals
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© LayerWise NV, all rights reserved © LayerWise NV, all rights reserved
LayerWise 4
Organization LayerWise
NV
Industrial
prototypes
engineering
series production
Medical
patient specific medical implants
Dental
patient specific dental prostheses
R&D
technology
material
software
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© LayerWise NV, all rights reserved © LayerWise NV, all rights reserved
Introduction to Additive Manufacturing 5
Basic
principles
Layer-by-layer manufacturing of 3D objects
Selective Laser Melting = AM technology using a focused laser beam to melt thin layers of powder metal
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© LayerWise NV, all rights reserved © LayerWise NV, all rights reserved
Introduction to Additive Manufacturing 6
Basic
principles
Layer-by-layer manufacturing allows unlimited shape complexity
Fully digital production technology, directly from CAD
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Introduction to Additive Manufacturing 7
Materials and
specifications
Materials:
Stainless steels (316L, 17-4 PH, etc.)
Hardenable steel
Bronze based alloy
Titanium (pure, Ti6Al4V, …)
Cobalt-chromium alloys (ASTM F75)
Inconel
Aluminium
…
Specifications
Maximum build volume 250x250x200 mm
Density 100 %
Typical part accuracy* ± 50 µm
Typical surface roughness* # 5 µm Ra – 40 µm Rz
Minimal wall thickness 0.15 mm
Minimal feature size 0.20 mm
* dependent on part geometry # can be improved by LayerWise SILC treatment
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Introduction to Additive Manufacturing 8
Melting
Characteristics
Resulting relative density up to 99.98 %
Ti6Al4V
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AM of dental implant prostheses 9
Result of R&D project @ K.U.Leuven; collaboration between dept. Mech. Engineering (Prof. JP Kruth – Dr. Ben Vandenbroucke) and dept. Prosthetic Dentistry (Prof. I. Naert)
Basic research started in 2004, finished in 2008
Research summary:
Proof of concept
Parameter and property optimization for Ti6Al4V and dental CoCrMo;
SLM optimization
Mechanical characterization
Chemical characterization
Development of model scanning;
Tactile scanning to measure implant positions
Laser triangulation to measure dental wax-up
Testing of design software
5 clinical cases
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Original workflow 10
Ditizing; tactile
scanning +
laser scanning
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Original workflow 11
Digital bridge
design; theory
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Original workflow 12
Digital bridge
design;
practice
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Original workflow 13
Manufactured
dental bridges
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AM of dental implant prostheses 15
Further
developments
Further developments @ LayerWise: Parameter and property
optimization Build rate improvement Surface roughness improvement Density improvement Mechanical property improvement
Development of model scanning; from tactile scanning and laser triangulation towards fringe-projection systems
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AM of dental implant prostheses 16
Further
developments
Integration of CNC controlled finishing of implant connections
Verification of total process accuracy
Development of design software
Development of implant connection library; currently 100+ connections
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AM of dental implant prostheses 17
Further
developments
Development of database software for order processing
Hiring people (engineers, dental technicians, salesforce)
Marketing
Pricing
…
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AM of dental implant prostheses 18
Further
developments
Additional development:
2 years time
Large investments
Commercially available since 2010
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© LayerWise NV, all rights reserved
Medical applications: dental prostheses 19
Implant supported dental prostheses Individual, custom design
Digital modeling and production
Higher accuracy; < 20 microns at implant interface
Improved surface retention
Gingival sealing edges = SealWise concept
Perfectly compatible with immediate loading protocols and intra-oral scanning
Less manual work
Less consumables
Patented technology by LayerWise
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© LayerWise NV, all rights reserved
Medical applications: dental prostheses 20
Patented technology by LayerWise
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© LayerWise NV, all rights reserved
Medical applications: dental prostheses 21
SealWise connections for improved sealing at gingival level
Patented technology by LayerWise
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© LayerWise NV, all rights reserved
Medical applications: dental prostheses 22
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© LayerWise NV, all rights reserved
Current service model 23
Future model; intra-oral scanning in dental practice
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Medical applications: custom implants 24
Custom
Implants
Patient-specific modeling of the implants; Based on medical
imaging data Pre-operative planning,
design, and production Trough partner
companies In close collaboration
with the surgeon!
Mimimal invasive two-piece zygoma implant, LayerWise NV
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Medical applications: custom implants 25
Total mandible
reconstruction Total mandible reconstruction
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Medical applications: custom implants 26
Total mandible
reconstruction Total mandible reconstruction
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Medical applications: custom implants 27
Total mandible
reconstruction
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Medical applications: custom implants 28
Custom
implants Custom acetabular
implants
Custom cranial implants
courtesy of Mobelife NV
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Medical applications: standard implants and instruments 29
Implant and
instrument
manufacturing
Window of interest:
Small to medium sized implants: CMF, trauma fixation, small articulation prostheses, bone screws, etc.
Interfacing with standard components (e.g. locking screws, PE inserts, etc.)
Complex instruments
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Medical applications: standard implants and instruments 30
Implant and
instrument
manufacturing
Ideal for small to medium batch sizes
Parallel manufacturing of different designs
Very short lead times
Allows reducing stock levels of implants and instruments!
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From R&D to business 31
General
observations
Time-to-market Make up a clear overview of work to be done:
Man months External testing and subcontracting Allowed development time! => Necessary work-force and budget
External verification! Need to work according to relevant standards Testing done by certified testing laboratory
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© LayerWise NV, all rights reserved © LayerWise NV, all rights reserved
From R&D to business 33
General
observations “Spin-off” title
Is very useful in the to gain visibility and to approach the academic world
May be a handicap in a business-to-business context …
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Contact details
LayerWise N.V.
Kapeldreef 60
3001 Leuven
Belgium
tel: +32 16 29 84 20
fax: +32 16 29 83 19
www.layerwise.com – www.dentwise.eu
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