Your SlideShare is downloading. ×
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases
Upcoming SlideShare
Loading in...5
×

Thanks for flagging this SlideShare!

Oops! An error has occurred.

×
Saving this for later? Get the SlideShare app to save on your phone or tablet. Read anywhere, anytime – even offline.
Text the download link to your phone
Standard text messaging rates apply

2013 03-12-masterclass-biomedical-applications-of-am fraunhofer-medical-cases

496

Published on

Additive manufacturing (AM) offers a few major benefits to biomedical applications. To improve the knowledge on AM possibilities, Sirris is organizing two different masterclasses. The first will …

Additive manufacturing (AM) offers a few major benefits to biomedical applications. To improve the knowledge on AM possibilities, Sirris is organizing two different masterclasses. The first will address the technology, materials used and applications, with experts in the matter explaining all relevant aspects.

Published in: Technology
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total Views
496
On Slideshare
0
From Embeds
0
Number of Embeds
0
Actions
Shares
0
Downloads
0
Comments
0
Likes
0
Embeds 0
No embeds

Report content
Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
No notes for slide

Transcript

  • 1. Masterclass: Biomedical applications of Additive ManufacturingPart 01: General considerations and clinical case studies
  • 2. Masterclass: Biomedical applications of Additive ManufacturingCase Study 4: New features and functions in implants through an innovative design approach and Additive Manufacturing (Laser Beam Melting)Thomas TöppelFraunhofer Institute for MachineTools and Forming Technology IWUChemnitz / Dresden (Germany)
  • 3.  The Fraunhofer IWU Motivation for biomedical Additive Manufacturing Laser Beam Melting Functional integration through Laser Beam Melting Active material combination for a non-loosening implant ConclusionsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 3
  • 4.  founded on July 1st, 1991 Itzehoe Lübeck about 510 employees Bremerhaven 29 million euro budget Bremen Project Group in Augsburg since Hannover Potsdam Berlin Teltow January 2009 Braunschweig Magdeburg Project Group in Zittau since Oberhausen Dortmund Halle Leipzig October 2011 Duisburg Schmallenberg Kassel Jena Dresden St. Augustin Aachen Euskirchen Zittau Chemnitz Wachtberg Ilmenau Darmstadt Würzburg Erlangen Bronnbach St. Ingbert Kaiserslautern Saarbrücken Karlsruhe Pfinztal Ettlingen Stuttgart Freising Freiburg Augsburg MünchenMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 4
  • 5.  Fields of expertise  in close cooperation with • Machine Tools • Chemnitz University of • Mechatronics Technology • Lightweight Construction • Fraunhofer-Gesellschaft • Forming Technologies • Machine tool industry • Cutting Technologies • German and international • Joining and Assembling automobile industry • Production Management • Ancillary industry (forming, cutting, tool and die making)Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 5
  • 6. Fraunhofer IWU Fraunhofer IWU IWP Chemnitz location Dresden location TU ChemnitzMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 6
  • 7.  Bio-mechanical characterization, design and numerical simulation Active materials for medical engineering Additive Manufacturing of implants with Laser Beam Melting Precision technology and micro-manufacturing Multifunctional light weight design and metal foam Bulk metal forming Based on clinical / medical demands and bio-mechanical analysis, we want to develop production technologies for functionally enhanced implantsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 7
  • 8.  The Fraunhofer IWU Motivation for biomedical Additive Manufacturing Laser Beam Melting Functional integration through Laser Beam Melting Active material combination for a non-loosening implant ConclusionsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 8
  • 9.  in Germany alone > 400.000 artificial joints (endoprostheses) implanted every year 90 % hip and knee joints main cause: arthrosis (wear of cartilage layer in joint) numbers are rising significantly (initial implantations as well as revision surgery)  cost explosion ever younger patients high demand for innovative endoprostheses (life cycle time ↑, complications ↓)Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 9
  • 10.  Idea: New features and functions in implants through an innovative design approach and Additive Manufacturing technology Together with surgeons / medical doctors 2 strategies were developed: Structured implants: • Internal functional cavities • Inner and surface structures • Better ingrowth behavior (secondary stability)Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 10
  • 11.  Idea: New features and functions in implants through an innovative design approach and Additive Manufacturing technology Together with surgeons / medical doctors 2 strategies were developed: Active components: • Shape Memory Alloy (SMA) to increase the implant stability • Anchoring function, better primary and secondary stabilityMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 11
  • 12.  The Fraunhofer IWU Motivation for biomedical Additive Manufacturing Laser Beam Melting Functional integration through Laser Beam Melting Active material combination for a non-loosening implant ConclusionsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 12
  • 13.  Direct, single step process, creating parts out of series-like metallic material  Complete local melting of the metal powder to a 99.5 - 100 % dense microstructurePrinciple sketch of a Laser Beam Melting machine Schematic diagram of Laser Beam MeltingMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 13
  • 14.  Fast cooling down of the melt pool up to 106 K/s  characteristic lamellar micro structure of LBM Heat treatment Ti-6Al-4V lamellar micro structure Ti-6Al-4V duplex micro structure (condition as built) (heat treated above beta transus temperature)Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 14
  • 15. time to product freedom of shape  no tools needed  arbitrarily complex geometries  no job preparation /  undercuts technology planning  internal geometric shapes  no NC programming  delicate structures  single step process  geometries not fabricable by cutting, forming or casting material diversity lightweight construction / bionics  aluminium  hollow and lattice-like  titanium structures  cobalt-chrome  100 % topology optimized parts  hot and cold work steel  bionic structures  nickel-base alloy (Inconel)  structures with graded porosityMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 15
  • 16. Heat treatment equipment Powder sieving machine LBM machine M2 Cusing by Concept LaserMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 16
  • 17.  The Fraunhofer IWU Motivation for biomedical Additive Manufacturing Laser Beam Melting Functional integration through Laser Beam Melting Active material combination for a non-loosening implant ConclusionsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 17
  • 18.  Manufacturing • Additive Manufacturing with Laser Beam Melting • Medically approved titanium alloy TiAl6V4 • Other materials possible (pure titanium, cobalt-chromium, stainless steel) • Manufacturing possible individually or in seriesMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 18
  • 19.  Design features – inner functional channels and cavities • Virtually unlimited freedom of design in shaping the channels and cavities, depending on desired function • High material and structural quality assure strength and stiffness of implant despite weakened cross sectionMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 19
  • 20.  Design features – inner lattice structure • Creation of periodic lattice structures in different shape and size • Stiffness adaption to the bone • Reduction of dead weightMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 20
  • 21.  Design features – macro-porous surface structure • Design of any desired surface structure • Creation of structures partially or on whole part • Depth/thickness of structure can be defined as desired • Better ingrowth 1000 µmMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 21
  • 22.  Functions – drug depot inside the implant • For post-surgery medical treatment of patient:  Improving wound healing  Promoting ingrowth  Pain relief  Preventing infections • With supply channels to implant-bone interface • Dosis and time period for release according to doctoral preceptMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 22
  • 23.  Functions – supply & distribution of bio-resorbable filler or bone cement • Central ingate and numerous supply channels towards implant-bone interface • To bridge gaps between implant and bone due to:  Fitting deficits of implant  Unexpectedly bad bone conditions  Already suffered loosening of implant • Prevention & treatment of loosening even years after implantation, avoiding revision surgeryMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 23
  • 24.  Functions – endoscopic inspection through the implant‘s inner body • Central ingate and numerous outlets towards implant-bone interface • Minimally invasive • Alternative to CT and MRT for post-surgery monitoringMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 24
  • 25.  Functions – other potential functions • Post-surgery drainage of blood and wound ooze through the implant‘s body • Support of revision surgery by feeding a medium for local dissolution of implant-bone joining for easier and faster explantation with less damage in sound bone structureMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 25
  • 26.  The Fraunhofer IWU Motivation for biomedical Additive Manufacturing Laser Beam Melting Functional integration through Laser Beam Melting Active material combination for a non-loosening implant ConclusionsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 26
  • 27.  Aim: homogeneous and stable fixation of Original Shape cementless hip stems Background: (aseptic) loosening of cementless Pseudoplastic hip implants caused by differences in the forming mechanical strength and elasticity of bone vs. implant Warming Solution: increase the primary stability by an optimal force distribution at the bone hip stem F interface using Shape Memory Alloy (SMA) Supressed Shape Memory Effect elements • Similar mechanical properties of SMA compared to bone material • Development of design as a basis for further studies and expert interviewsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 27
  • 28.  Question: "traditional or modern" classical short stem prosthesis as preferred variant Preliminary sketches for SMA element integration as a basis for survey among surgeonsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 28
  • 29.  2 principles of integrating SME elements were investigated Joined integrally within LBM process  Mounted with positive locking Disadvantages • Limited freedom of design • Cleaning issuesMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 29
  • 30.  Development of SMA mounting method – first functional models body / fixation in implant mounted SMA sheet (sectional view) (side view)Five variants of different geometry consisting of a base body and a SMA sheet Possible areas of ​application Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 30
  • 31. Hip stem with SMA elements  cool down ≤ 0 °C Active principle: Implantation in femur Activation by body temperature T Cooled Body temperature Generating an additional force in the contact area of the SMA sheets between hip stem and femur Aim: Stabilization of cementless hip stemMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 31
  • 32.  Determination of the SMA induced forces – experimental set up • Z020 universal testing machine Zwick / Roell with integrated temperature chamber • Heating up to body temperature and measuring of the transmitted forces Upper pressure plate Functional model Lower pressure plateMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 32
  • 33.  Determination of the SMA induced forces – forces during and after thermal activation Theory Experiment F (t)F (15 min) 64 N 1 36°C 0,95 tA 15 min t Activation time tA = 62 s, contact forces up to 80 NMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 33
  • 34.  LBM manufactured hip stem with SMA sheet actuators – final designMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 34
  • 35.  Demonstrator – femoral hip stem with SMA sheet actuators • Standard stem prosthesis with SMA elements support a homogenous force distribution on the stem/bone-interface • Hip stem manufactured by AM in Ti-6Al-4V • Cone with standard size (12/14) • Lower end of the shaft polished  only axial guiding function • SMA elements:  NiTi alloy, biocompatible  Activation at body temperature  Biocompatible coating of prosthesis and SMA Hip stem with SMA actuators elements (Fraunhofer FEP, Dresden)Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 35
  • 36.  The Fraunhofer IWU Motivation for biomedical Additive Manufacturing Laser Beam Melting Functional integration through Laser Beam Melting Active material combination for a non-loosening implant ConclusionsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 36
  • 37.  Additive Manufacturing of implants with Beam Melting Technology enables unforeseen freedom in implant design Besides patient-specific design and surface structuring, the integration of functions and added value in implants is another, new field of application for Additive Manufacturing technology in endoprosthesis Inner functional channels and cavities supply implants with completely new and additional functions AM enables the integration of active SMA elements Added value of these implants satisfy higher manufacturing costs?! Less revision surgery, lower inter- and post-operative risks, more comfort for patientsMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 37
  • 38.  Further development of the implant prototypes In-vitro and in-vivo tests Goal: introduction of implant with functional channels and cavities (MUGETO®) and active implant as medically approved product to be implanted in humans Partners wanted to reach that goal!Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 38
  • 39. Thomas Toeppel Group »Additive Manufacturing Technologies« Fraunhofer Institute for Machine Tools and Forming Technology IWU Postal address: Visitor address: Reichenhainer Str. 88 Noethnitzer Str. 44 09126 Chemnitz 01187 Dresden Germany Germany Phone: + 49 (351) 4772-2152 Fax: + 49 (351) 4772-2303 E-mail: thomas.toeppel@iwu.fraunhofer.deMasterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 39

×