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Engineering on Human Anatomy
Presented by David Flynn
Materialise USA
Committed to innovations for a
better and healthier ...
About Materialise
• Company
• Established 1990
• Leuven, Belgium
• ±1000 employees
• Worldwide presence
2
We are Materialise
3
Additive
Manufacturing
Services
Industrial
Prototyping &
Mfg Services
Software for
Additive
Manufactu...
Diversity means strength
Courtesy of TotalSim Ltd.
Courtesy of IDEE / Maastricht Instrument
4
Mimics Innovation Suite:
Our Total Solution
• Mimics®
• Processing software to take 2D
image (CT, MRI, etc.) to
construct ...
Medical scanner (CT/MR/US)
Your own PC or laptop
Mimics
3-matic ®
• Design and meshing software ideally suited for use
with anatomical data
7
Design: custom cranial plate Meshing...
Case Studies
•Visual and Diagnostic Aids:
• Medical Models
• Surgical Intervention
•Engineering Functionality:
• Surgical ...
MEDICAL MODELS AS
VISUALIZATION AND
DIAGNOSTIC AIDS
9
Medical Models
• Separate conjoined twins
• Arteries could not be tracked with X-rays
• Operation time reduced from 97 to ...
Medical Models
• 3D ultrasound with tomographic output
11
Jorge Santos et al. 2009, Royal College of Art, UK
MEDICAL MODELS USED FOR
SURGICAL INTERVENTION
12
SURGICAL INTERVENTION CASE
STUDY: AORTIC DISSECTION
13
Case Study: Aortic Dissection
•Demographics
• Incidence 1-10:100,000
• Rarely < 60
• Mostly male
•Medical emergency
• Tear...
Modeling from CT images
Outcomes
• No intervention possible
• Model revealed multiple leakage paths in need of
repair
• Location of leakage paths ...
SURGICAL INTERVENTION CASE
STUDY: CONGENITAL CARDIAC
MALFORMATION
17
Case: Congenital Cardiac Malformation
• Irregular Anatomy
• No two cases are the same
• Provides guidance for the
surgeon
...
How was it created?
Emory University Hospital
SURGICAL GUIDES: TOTAL
KNEE REPLACEMENT
20
Patient Specific Guides
for Total Knee Replacement
Scan
Patient
Construct
3D models
Plan the
surgery
Design &
build guides...
Scan
Patient
Construct
3D models
Plan the
surgery
Design &
build guides
Enter the
OR
Patient Specific Guides
for Total Kne...
Scan
Patient
Construct
3D models
Plan the
surgery
Design &
build guides
Enter the
OR
Patient Specific Guides
for Total Kne...
Scan
Patient
Construct
3D models
Plan the
surgery
Design &
build guides
Enter the
OR
Laser Sintering
(LS)
Patient Specific...
Scan
Patient
Construct
3D models
Plan the
surgery
Design &
build guides
Enter the
OR
Patient Specific Guides
for Total Kne...
SURGICAL GUIDES: CMF
26
CMF Software & Surgical Guides
Upload CT
data
Perform Planning
session online with
Materialise
Printing of planning
outcom...
Case presented by Daniel Buchbinder, MD DMD, Beth Israel New York
CMF Software & Surgical Guides
Guide Benefits
• Increase collaboration between doctors
• Reduced cost and complexity of procedure
• Decrease the number o...
Guide Production
• 5 dedicated LS machines in Belgium
• Started USA Production 2010
• Key partners in USA
• Surgeons predo...
PATIENT SPECIFIC
IMPLANTS
31
• Design in 30 minutes
• Design was watertight and ready to print
• Model printed in Ti6Al4V with EBM (Arcam)
Custom Impla...
Custom Implant Design
• Cranio-Plate
• Porosity Built In
Patient specific implant design
• Increasing demand
for revision total hip arthroplasty
• Growing number primary implants
...
Patient-Specific Acetabular Cup Implant
35
Segmentation/reconstruction
of anatomy Custom fit implant designed Automated sc...
Patient specific implant design using FEA
• Model results
• Manufacturing (selective laser melting)
36
Implant integrity B...
Custom Implants– Acetabular Cup
• Custom Acetabulum Implant
Where do we go from here?
• Future of healthcare is customization
• Key to better patent care lies in patient specific sol...
Thank you!
dave.flynn@materialise.com
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Inside3DPrinting_DaveFlynn

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Transcript of "Inside3DPrinting_DaveFlynn"

  1. 1. Engineering on Human Anatomy Presented by David Flynn Materialise USA Committed to innovations for a better and healthier world Inside 3D Printing San Jose, CA 09/18/13
  2. 2. About Materialise • Company • Established 1990 • Leuven, Belgium • ±1000 employees • Worldwide presence 2
  3. 3. We are Materialise 3 Additive Manufacturing Services Industrial Prototyping & Mfg Services Software for Additive Manufacturing • Magics • Streamics • 3-Matic Biomedical Engineering Mimics Innovation Suite Cranio-Maxillo Facial Clinical Service RapidFit+ Custom modular fixture development service i.Materialise Online 3D Printing Services .MGX Additive Manufactured Artwork Orthopaedics Clinical Service PRODUC- TION PRODUC- TION SOFTWARESOFTWARE SERVICESSERVICES
  4. 4. Diversity means strength Courtesy of TotalSim Ltd. Courtesy of IDEE / Maastricht Instrument 4
  5. 5. Mimics Innovation Suite: Our Total Solution • Mimics® • Processing software to take 2D image (CT, MRI, etc.) to construct 3D models • 3-matic® • Design and meshing software ideal for anatomical data • Services • Anotomical Models, HeartPrint • Engineering services 5
  6. 6. Medical scanner (CT/MR/US) Your own PC or laptop Mimics
  7. 7. 3-matic ® • Design and meshing software ideally suited for use with anatomical data 7 Design: custom cranial plate Meshing: vertebrae remeshing
  8. 8. Case Studies •Visual and Diagnostic Aids: • Medical Models • Surgical Intervention •Engineering Functionality: • Surgical Guides • Patient Specific Implants 8
  9. 9. MEDICAL MODELS AS VISUALIZATION AND DIAGNOSTIC AIDS 9
  10. 10. Medical Models • Separate conjoined twins • Arteries could not be tracked with X-rays • Operation time reduced from 97 to 22 hours 10 Kenneth E. Salyer, M.D. and Objet Geometries Ltd., 2002
  11. 11. Medical Models • 3D ultrasound with tomographic output 11 Jorge Santos et al. 2009, Royal College of Art, UK
  12. 12. MEDICAL MODELS USED FOR SURGICAL INTERVENTION 12
  13. 13. SURGICAL INTERVENTION CASE STUDY: AORTIC DISSECTION 13
  14. 14. Case Study: Aortic Dissection •Demographics • Incidence 1-10:100,000 • Rarely < 60 • Mostly male •Medical emergency • Tear in inner wall of aorta • Blood flows between layers • True vs false lumen • 80% mortality rate if rupture occurs
  15. 15. Modeling from CT images
  16. 16. Outcomes • No intervention possible • Model revealed multiple leakage paths in need of repair • Location of leakage paths closer to neck arteries than originally thought • Comorbidity risks too high • Gave tangible view on leakage paths and relation to connecting anatomy • Modeling software and 3D printed model helped identify new risks
  17. 17. SURGICAL INTERVENTION CASE STUDY: CONGENITAL CARDIAC MALFORMATION 17
  18. 18. Case: Congenital Cardiac Malformation • Irregular Anatomy • No two cases are the same • Provides guidance for the surgeon • Benefits • Anatomically accurate • Capture arrangement of chambers and GV • Model characteristics • Flexible to mimic soft tissue • Ability to bend and cut Emory University Hospital
  19. 19. How was it created? Emory University Hospital
  20. 20. SURGICAL GUIDES: TOTAL KNEE REPLACEMENT 20
  21. 21. Patient Specific Guides for Total Knee Replacement Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR
  22. 22. Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Patient Specific Guides for Total Knee Replacement
  23. 23. Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Patient Specific Guides for Total Knee Replacement
  24. 24. Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Laser Sintering (LS) Patient Specific Guides for Total Knee Replacement
  25. 25. Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Patient Specific Guides for Total Knee Replacement
  26. 26. SURGICAL GUIDES: CMF 26
  27. 27. CMF Software & Surgical Guides Upload CT data Perform Planning session online with Materialise Printing of planning outcome: Models and/or guides Synthes to deliver models, guides and / or implants
  28. 28. Case presented by Daniel Buchbinder, MD DMD, Beth Israel New York CMF Software & Surgical Guides
  29. 29. Guide Benefits • Increase collaboration between doctors • Reduced cost and complexity of procedure • Decrease the number of surgical instruments to sterilize • Potential to decrease OR time • Expedite patient recovery • Increase longevity of implants • Allow surgeon to try different approaches before lifting a scalpel • Avoid making critical decisions on the spot
  30. 30. Guide Production • 5 dedicated LS machines in Belgium • Started USA Production 2010 • Key partners in USA • Surgeons predominently in USA • 3 LS Machines 6 by end of 2011 in Plymouth, MI • Room to grow to 24 machines! • Medical Production Focus in USA (growth)
  31. 31. PATIENT SPECIFIC IMPLANTS 31
  32. 32. • Design in 30 minutes • Design was watertight and ready to print • Model printed in Ti6Al4V with EBM (Arcam) Custom Implant Design- 3-matic®
  33. 33. Custom Implant Design • Cranio-Plate • Porosity Built In
  34. 34. Patient specific implant design • Increasing demand for revision total hip arthroplasty • Growing number primary implants • 15% require revision • >50% involve acetabular component • Extensive bone loss • Complex defects • Patient-specific surgical planning • Custom implant design 34 Mechanical loosening Hip instability Infection Fracture
  35. 35. Patient-Specific Acetabular Cup Implant 35 Segmentation/reconstruction of anatomy Custom fit implant designed Automated screw placement based on bone thickness Mesh refinement of bone and implant assembly CourtesyofBartelsetal.KULeuven CT-derived material properties Patient-specific MSM
  36. 36. Patient specific implant design using FEA • Model results • Manufacturing (selective laser melting) 36 Implant integrity Bone loading
  37. 37. Custom Implants– Acetabular Cup • Custom Acetabulum Implant
  38. 38. Where do we go from here? • Future of healthcare is customization • Key to better patent care lies in patient specific solutions tailored to individual anatomy
  39. 39. Thank you! dave.flynn@materialise.com
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