Medical Additive ManufacturingOrthopaedics

Bralco Advanced Materials Pte. Ltd. Singapore

Contents Overview of Medical Additive Manufacturing (AM)

Identifying Challenges

Motivation

Products

Materials Development

Market Trends

Case Studies

Overview: Leveraging on the Potential of Medical AM

Materials System

❖ Polymers

❖ Metals and its Alloys

Applications

❖ Surgical Instrumentation - Cutting and drilling guides, special instrumentation etc

❖ Orthopaedic Implants - Standard and customized implants

❖ Dental Implants

❖ External Prostheses

Overview: Why AM or 3D Printing in Orthopaedics?

1 AM gives a flexible and substitution solution where customized implants can be formed as per required shape and size.

2 Simulation in AM will gain an accurate perception of patient’s anatomy (bone’s structure, porosity, surface texture etc.) thus helpful for highly complex surgical pathologies (bone ingrowth around the implant).

3 Solve unique data of each patient is different from one another.

Adoption of AM - Orthopaedics

In 2017, there are a number of standard additively manufactured orthopaedic implants that have made it all the way into (relatively) high volume production. Acetabular systems for hip replacements were one of the earliest 3D printed medical implants to receive approval and accreditation and standard knee and spinal implant devices produced with AM are catching up, with ankle implant systems also making progress.

Source: SmarTech Publishing – Additive Orthopedics: Markets for 3D-Printed Medical Implants – 2017

Identifying Challenges in Orthopaedics

❏ Certification and medical approvals for customized implants.❏ Biocompatible materials.❏ Quality assurance.❏ Geometry assurance and resolution.❏ Efficient post processing of customized parts.

Motivation and Additive Manufacturing on Demand

Individualization - Patient-specific customization to ensure minimally invasive best-fit devices.

Functional Integration - Integrated trabecular or free-form structures in 1 implant. E.g. A porous structure and rough surface, improving bone integration.

Flexible and Efficient - No change in hardware configuration leads to minimal waste. Shortened lead time.

Reduced Surgical Costs - Finely customized devices will speed up in-hospital process of 3D scan-to-part.

Complex Geometry Possibilities - Mimic bionic principles of complexity in order to accelerate the patient’s healing process.

The Growth of Additive Orthopaedics

Materials Development for Orthopaedic Use

Product Title: Acetabular Cup Hip Replacement Implant

Example of Biocompatible Materials: Ti6Al4V ELI Titanium Alloy and Polymethylmethacrylate (PMMA) (socket)

Metal AM Process: Electron Beam Melting (EBM)

Delta-TT Cup by Lima Corporate

Materials Development for Orthopaedic Use Product Title: Spinal Implant

Examples of Biocompatible Materials: Titanium Alloy, Cobalt Chrome

Metal AM Process: Selective Laser Melting (SLM)

Tritanium® PL Interbody Cage by STRYKER

Ti-LIFE Technology JULIET® 3D Titanium Interbody Devices by SPINEART

Modulus® XLIF® titanium implants by Nuvasive

Materials Development for Orthopaedic Use

Product Title: Knee Replacement Implant

Examples of Biocompatible Materials

Metals: Titanium-Tantalum,Cobalt Chromium Alloys, Oxinium Oxidized Zirconium

Polymer: Ultra High Molecular Weight Polyethylene (UHMWPE)

Metal AM Process: Selective Laser Melting (SLM) and Electron Beam Melting (EBM)

VERILAST™ Knee Replacement Implant by Smith and Nephew

Case Study 1

Case Study 2

Case Study 3

Case Study 4

Case Study 5

Morriston Hospital in Swansea

ReferencesState-of-the-art for Additive Manufacturing of Metals. http://www.metalliskamaterial.se/globalassets/3-forskning/rapporter/2016-03898---state-of-the-art-for-additive-manufacturing-of-metals-2_1.pdf

Additive manufacturing applications in orthopaedics: A review. https://www.researchgate.net/publication/324681846_Additive_manufacturing_applications_in_orthopaedics_A_review

Additive Manufacturing: Scientifc and Technological Challenges, Market Uptake and Opportunities. https://www.sciencedirect.com/science/article/pii/S1369702117301773

Progressing Orthopedic Implants with Additive Manufacturing. https://www.3dprintingmedia.network/progressing-orthopedic-implants-additive-manufacturing/

EBM Materials. http://disanto.com/technology/additive-manufacturing/ebm_materials/

Arcam Systems Produced Over 100,000 3D Printed Hip Cups Since 2007. https://www.3dprintingmedia.network/arcam-produced-100000-3d-printed-hip-cups-since-2007/

Will Additive Manufacturing Become the Leading Production Method for the Orthopedic Industry? https://www.3dprintingmedia.network/will-additive-manufacturing-become-leading-production-method-orthopedic-industry/

GE Additive and Stryker Announce Additive Manufacturing Partnership for Orthopedic Implants. https://www.3dprintingmedia.network/ge-additive-stryker-announce-additive-manufacturing-partnership-orthopedic-implants/

Additive Manufacturing for Orthopedic Implants to Generate More Than $1B+ by 2026. https://www.3dprintingmedia.network/additive-manufacturing-orthopedic-implants-generate-1b-2026/

Additive Manufacturing in Spine: The future is here. Why are 5 of the Leading Companies launching 3D Cages?

http://www.thespinemarketgroup.com/additive-manufacturing-in-spine-the-future-is-here-why-are-5-of-the-leading-companies-launching-3d-cages/

How Metal Additive Manufacturing Improves Common Types of Medical Implants.https://www.farinia.com/additive-manufacturing/industrial-3d/metal-additive-manufacturing-improves-common-medical-implants

Additive Manufacturing Technology For Orthopaedic Implants. https://www.exac.com/additive-manufacturing-technology-for-orthopaedic-implants/

Knee Replacement Implant Materials. https://bonesmart.org/knee/knee-replacement-implant-materials/

VERILAST™ Technology. https://bonesmart.org/sponsors/smith-nephew/?source=video

https://www.odtmag.com/issues/2018-03-01/view_features/impact-of-additive-manufacturing-on-the-orthopedic-industry

http://en.people.cn/n3/2017/0810/c90000-9253783.html

3d Printed Jaw Implant Bone Graft. https://3dprint.com/191800/3d-printed-jaw-implant-bone-graft/

The growing market for additive manufacturing in medical sector. https://www.3dnatives.com/en/medical-additive-manufacturing070520174/

https://www.dailymail.co.uk/news/article-4864386/Australian-man-gets-new-3D-PRINTED-leg-bone-world-first.html

https://www.eos.info/press/case_study/additive_manufactured_hip_implant

Questions?

Thank You

Bralco Advanced Materials Pte. Ltd. Singapore

"Materials by Design, Manufacturing on Demand".

Innovation Centre:# 03-66, JTC Launchpad @ One North, 81 Ayer Rajah Crescent,Singapore 139967

Phone: +65-68165950Fax: +65-68165951Email: info@bralcoadvancedmaterials.com Web: www.bralcoadvancedmaterials.com