additive manufacturing for biomedical applications
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The utility of additive manufacturing technologies in the medical field. An overview of existing and future technologies and applicationsTRANSCRIPT
le centre collectif de l’industrie technologique belge
Additive Manufacturing for Biomedical applications
Grégory Nolens & Carsten Engel
Workshop, January 23th 2014
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 2
130 experts & high-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”
3
Additive Manufacturing/3D Printing :
Basic Principles
Basic data :
Layer by layer manufacturing
3D CAD File 3D STL File Sliced File
Starting point:
3D CAD file
CENG
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
3D Printing – Next
• Obama said (feb. 2013): "A once-shuttered warehouse is
now a state-of-the art lab where new workers are mastering
the 3-D printing that has the potential to revolutionize the
way we make almost everything“
“We can’t wait” initiative
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 4
Fashion effect – public machine
• Design, gadget,
• but also functional and caring
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 5
Industrial and technical products
• Prototyping
• No assembly
• Personalized
• Technical
• Porous
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 6
23/01/2014 7
Additive Manufacturing : Basic Principles
Advantages of using AM … try something new !
• Low-cost ability to easily try out ideas generates many
innovations
• AM has seen children returning to making things. From
digital into reality.
• Testing the market with an idea with small production
• Alows inventors to realize their inventions and test
their market
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
23/01/2014 8
Additive Manufacturing : challenges
Variety of materials still not vast enough
Lack of precision on some technologies
Machines still very pricy (industrial)
Need of certification and qualification of materials & process
Lack of surface quality and finishing
Not suited for big series (automobile)
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
9
Additive Manufacturing technologies @ Sirris
SIRRIS – European 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)
• Mcor - paper
• Bi-material FDM system
CENG
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
23/01/2014 10
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 2012 Charleroi | www.sirris.be | [email protected] |
CENG
[Sirris ADD]
[Sirris ADD]
[Sirris ADD]
The utility of Additive Manufacturing technologies
in the medical field
11
Medical Additive Manufacturing Software:
ADD capacities & competencies
CENG
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] |
• Materialise: Mimics
• Materialise: 3matic
• Marcam: Autofab
• Able Software Corp: 3D Doctor
• Medicim: Maxilim
• ProEngineer
• New: Lenexa: Analyze
• New: Brisbane: Anatomics
• (…)
[Mimics & 3-matic - Materialise]
23/01/2014 12
Additive Manufacturing in the medical field
Leading applications:
• Custom implant manufacture (Scanning/Custom Prosthesis Design) • Pre-surgical planning • Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
[Z. Corp Medical Modeling Solutions]
[Z. Corp Medical Modeling Solutions]
[Arcam & Objet technology]
[Sirris ADD]
23/01/2014 13
Leading applications:
• Pre-surgical planning:
• Implant pre-contouring • Screw trajectory • Screw selection/location • Instrument selection • Technique rehearsal
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
[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 Rapid Prototyping / Manufacturing in
the medical field
23/01/2014 14
Medical Field: CASE STUDIES @ SIRRIS
Leading applications:
• Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
[Sirris ADD] [Sirris ADD]
[Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD]
23/01/2014 15
Medical Field: CASE STUDIES @ SIRRIS
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
Spinal & CMF case studies in ceramic
• Porous scaffolds for Spine surgery
• In vivo testing for bone integration
• Validation production by Sirris Tech transfer
• Field: Maxillofacial Surgery in France, production in Belgium
[Sirris ADD]
[Sirris ADD] [Sirris ADD]
16
Medical field: Industrial Case studies
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
Project: “In vitro testing models - arteries”
• Goals:
• To gain biomechanical know-how
• Virtual prototyping, device testing, virtual design iterations
• Diagnostic research
• Technologies involved: Connex Eden 500 bi-material 3D inkjet printing
23/01/2014
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Medical Field: CASE STUDIES @ SIRRIS
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
Surgical Cutting Templates
• UCL-St Luc (Belgium) • UCL spin-off: VISYOS • Polyamide cutting patient-custom cutting tools
• SLS technology + bio-coating
[VISYOS] [VISYOS]
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Medical Field: CASE STUDIES @ SIRRIS
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
Surgical Cutting Templates – reimbursement problem
Surgical guides not reimbursed, but facts are:
- 1 min. in surgical theatre (estimated): 60€
- Mean of orthopedic surgery duration: 5-12h (18k-44k€)
- Surgical guide can reduce: 20-70% of the duration (TBC)
- Surgical guide cost: 50-300€
- Economy: estimated 3-30k€/surgery
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Medical Field: CASE STUDIES in the world
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
23/01/2014
[Dr J. Poukens – Uhasselt, Xilloc Medical (Maastricht)]
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World’s first total mandible implant in Titanium
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
23/01/2014
[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]
21 © sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)
23/01/2014
Towards newly designed implants
[Université de Mons, Faculté Polytechnique]
22 © sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
23/01/2014
The future of bio-manufacturing…not so far away!
23
process of printing biologically relevant materials (such as cells,
tissues, and biodegradable biomaterials) that will accomplish
one or more biological functions
What’s Bioprinting
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
+
cells
Bio-glue
3D machine
Tissues/organs Scaffolds
+ cells
23/01/2014 24 © sirris 2012 Charleroi | www.sirris.be | [email protected] |
Bioprinting – an emerging technology
Bioprinting place in emerging technologies, from the Hype Cycle for Emerging
Technologies 2013- Gartner
25
Market approach interest for companies?
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Applications:
• Drug discovery & Assays
• Cell therapy + Tissue Engineering
• Bioprocess
• In vitro diagnostic & research
• Food
26
Drug Discovery and Assays
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Facts: Drug Discovery and Assays
• 90-95% of drugs approved on animal (mouse, rabbit, etc.), was not
for human lot of money lost, ethic problem
• Animal use: 10-100 Mio in US/year
• European Comission banning: FULL on cosmetic (2013), next
pharma (?)
27
Drug Discovery and Assays
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Applications:
• Drug screening w/o animal
& less deviations
Pharmaceutical area
Drug X
Disease tissue
Treated tissue
Organovo’s targeted market
28
Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Facts: Tissue engineering
• Alternative to donor waiting list
• Limited available « material » resource (skin, organs, cells, …)
29
Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Facts: Cell Therapy
Cell therapy industry market
(2008–2014).
Graph showing the estimated
CTI revenues from 2008–2014
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Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Facts: Cell Therapy
High potential for
Small defect repair
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Cell Therapy & Tissue engineering
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Applications:
• Large defect repair
32
Drug Discovery and Assays
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Applications:
• Biocompatibility assays w/o animals (ISO)
Artificial skin Irritation
33
Technological approach
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Applications:
• In vitro diag and Research
• Biomarker
• Drug kinetic
• Pathogen reaction
34
Biotechnolgies & Bioprocess
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Applications:
• Biomolecule production in 3D
• Machine producers
35
Food & Agriculture
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
• Applications:
• New food process?
Focus on food player with Life
Science approach: biomaterial
( e.g. Tissue engineering)
Bioprinting
• Where beginning R&D?
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 36
Tissue engineering basics
• Lamarck (1744–1829): La fonction crée l’organe
(The function creates the organ).
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 37
Tissue engineering basics
• Lamarck (1744–1829): the function creates the organ.
daylife example: tissue reacts to device
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 38
« 2nd skin » development
Tissue engineering basics
• One scaffold can be enough
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 39
Tube with structure mimicking vascular matrix Rat implantation
Cell infiltration differentiation scaffold disapear tissue restorated
Tissue engineering basics
Scaffolds + stem cells + growth factors = work better
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 40
Artificial heart tissue (Taylor, Minnesota, 2009)
Artificial kidney tissue
Scaffolds come from animal washed for cells
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 41
Personalized
scaffolds
incubation with
stem cells
IPL, UGent, …
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 42
Nanostructure for
fluidic, cell interaction,
scaffold,…
2PP (two photon
polymerisation)
Very small devices
Nanoscribe
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 43
Industrial machines
Personalized
scaffolds
incubation with
stem cells
(and cell printing)
EnvisionTech, GESIM, Regenovo (China)…
3D Bioprinting solutions
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 44
Personalized
scaffolds +
stem cells
incubation
Bioprinting players in the world
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 45
• Keyplayers outside Europe
• Dr. Shinya Yamanaka (JPUS): stem cells
• Dr. Anthony Atala (US, Boston)
• Wake Forest University (US, North Carolina)
• ACES (Australia) biopen
• China
Bioprinting players in Europe – few
23/01/2014 © sirris 2012 Charleroi | www.sirris.be | [email protected] | 46
47
CENG
« Medical Additive Manufacturing & Rapid Prototyping »
« Sirris »
© sirris 2012 Charleroi | www.sirris.be | [email protected] | 23/01/2014
48
Sirris Additive Manufacturing: Contact
© sirris 2012 Charleroi | www.sirris.be | [email protected] |
CENG
23/01/2014
Carsten ENGEL, Ir, MBA
Department of Additive Manufacturing
Mail: [email protected]
Mobile: +32 498 91 94 50
Skype: Carsten-Engel
SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be
Grégory NOLENS, PhD
Department of Additive Manufacturing
Mail: [email protected]
Mobile: +32 498 91 94 75
Skype: gnolens
SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be