Inside3DPrinting_DaveFlynn
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Inside3DPrinting_DaveFlynn

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Inside3DPrinting_DaveFlynn Inside3DPrinting_DaveFlynn Presentation Transcript

  • 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
  • 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 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
  • 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 3D models • 3-matic® • Design and meshing software ideal for anatomical data • Services • Anotomical Models, HeartPrint • Engineering services 5
  • 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: vertebrae remeshing
  • Case Studies •Visual and Diagnostic Aids: • Medical Models • Surgical Intervention •Engineering Functionality: • Surgical Guides • Patient Specific Implants 8
  • 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 22 hours 10 Kenneth E. Salyer, M.D. and Objet Geometries Ltd., 2002
  • 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 in inner wall of aorta • Blood flows between layers • True vs false lumen • 80% mortality rate if rupture occurs
  • Modeling from CT images
  • 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
  • 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 • Benefits • Anatomically accurate • Capture arrangement of chambers and GV • Model characteristics • Flexible to mimic soft tissue • Ability to bend and cut Emory University Hospital
  • 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 Enter the OR
  • Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Patient Specific Guides for Total Knee Replacement
  • Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Patient Specific Guides for Total Knee Replacement
  • Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Laser Sintering (LS) Patient Specific Guides for Total Knee Replacement
  • Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR Patient Specific Guides for Total Knee Replacement
  • SURGICAL GUIDES: CMF 26
  • 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
  • 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 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
  • 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)
  • PATIENT SPECIFIC IMPLANTS 31
  • • Design in 30 minutes • Design was watertight and ready to print • Model printed in Ti6Al4V with EBM (Arcam) Custom Implant Design- 3-matic®
  • Custom Implant Design • Cranio-Plate • Porosity Built In
  • 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
  • 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
  • Patient specific implant design using FEA • Model results • Manufacturing (selective laser melting) 36 Implant integrity Bone loading
  • 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 solutions tailored to individual anatomy
  • Thank you! dave.flynn@materialise.com