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 applications

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Additive manufacturing for biomedical applications

  1. 1. Additive Manufacturing for Biomedical applications Grégory Nolens & Carsten Engel Workshop, January 23th 2014 le centre collectif de l’industrie technologique belge
  2. 2. Mission Collective centre of the technology industry • Non profit organization • Industry owned “Increase the competitiveness of companies of the Agoria sectors through technological innovations” 130 experts & high-tech infrastructure 4,700 industrial interventions (advice, projects, services) •within 1,700 different companies •whose 75% are SME’s •24M EUR turnover © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 2
  3. 3. Additive Manufacturing/3D Printing : Basic Principles Basic data : Layer by layer manufacturing Starting point: 3D CAD file 3D CAD File 3D STL File Sliced File © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 3
  4. 4. 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 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 4
  5. 5. Fashion effect – public machine • Design, gadget, • but also functional and caring © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 5
  6. 6. Industrial and technical products • • • • • Prototyping No assembly Personalized Technical Porous © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 6
  7. 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 | info@sirris.be | 23/01/2014 7
  8. 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 | info@sirris.be | 23/01/2014 8
  9. 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 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 9
  10. 10. The utility of Additive Manufacturing technologies in the medical field 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 ADD] [Sirris ADD] [Sirris ADD] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 10
  11. 11. ADD capacities & competencies Medical Additive Manufacturing Software: • • • • • • • • • Materialise: Mimics Materialise: 3matic Marcam: Autofab Able Software Corp: 3D Doctor Medicim: Maxilim ProEngineer New: Lenexa: Analyze New: Brisbane: Anatomics (…) [Mimics & 3-matic - Materialise] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 11
  12. 12. Additive Manufacturing in the medical field Leading applications: • Custom implant manufacture (Scanning/Custom Prosthesis Design) • Pre-surgical planning [Arcam & Objet technology] • Physician to physician communication • Powerful patient presentation tool [Z. Corp Medical Modeling Solutions] • Medical student/resident education [Sirris ADD] [Z. Corp Medical Modeling Solutions] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 12
  13. 13. The utility of Rapid Prototyping / Manufacturing in the medical field Leading applications: “No matter how good our 3-D graphics are, there is nothing like a model in your hands . . .” • Pre-surgical planning: • Implant pre-contouring • Screw trajectory • Screw selection/location • Instrument selection • Technique rehearsal [Objet] [Objet] [Objet Connex Eden 500] [Objet] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 13
  14. 14. Medical Field: CASE STUDIES @ SIRRIS Leading applications: • Physician to physician communication • Powerful patient presentation tool • Medical student/resident education [Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 14
  15. 15. Medical Field: CASE STUDIES @ SIRRIS 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] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 15
  16. 16. Medical field: Industrial Case studies 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 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 16
  17. 17. Medical Field: CASE STUDIES @ SIRRIS Surgical Cutting Templates • UCL-St Luc (Belgium) • UCL spin-off: VISYOS • Polyamide cutting patient-custom cutting tools • SLS technology + bio-coating [VISYOS] [VISYOS] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 17
  18. 18. Medical Field: CASE STUDIES @ SIRRIS 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 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 18
  19. 19. Medical Field: CASE STUDIES in the world [Dr J. Poukens – Uhasselt, Xilloc Medical (Maastricht)] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 19
  20. 20. World’s first total mandible implant in Titanium [UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 20
  21. 21. Towards newly designed implants Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS) [Université de Mons, Faculté Polytechnique] © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 21
  22. 22. The future of bio-manufacturing…not so far away! © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 22
  23. 23. What’s Bioprinting process of printing biologically relevant materials (such as cells, tissues, and biodegradable biomaterials) that will accomplish one or more biological functions 3D machine cells Bio-glue + Scaffolds + cells Tissues/organs © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 23
  24. 24. Bioprinting – an emerging technology Bioprinting place in emerging technologies, from the Hype Cycle for Emerging Technologies 2013- Gartner © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 24
  25. 25. Market approach  interest for companies? • Applications: • Drug discovery & Assays • Cell therapy + Tissue Engineering • Bioprocess • In vitro diagnostic & research • Food © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 25
  26. 26. Drug Discovery and Assays • 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 (?) © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 26
  27. 27. Drug Discovery and Assays • Drug X Applications: • Drug screening w/o animal & less deviations Pharmaceutical area Disease tissue Treated tissue Organovo’s targeted market © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 27
  28. 28. Cell Therapy & Tissue engineering • Facts: Tissue engineering • Alternative to donor waiting list • Limited available « material » resource (skin, organs, cells, …) © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 28
  29. 29. Cell Therapy & Tissue engineering • Facts: Cell Therapy Cell therapy industry market (2008–2014). Graph showing the estimated CTI revenues from 2008–2014 © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 29
  30. 30. Cell Therapy & Tissue engineering • Facts: Cell Therapy High potential for Small defect repair © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 30
  31. 31. Cell Therapy & Tissue engineering • Applications: • Large defect repair © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 31
  32. 32. Drug Discovery and Assays • Applications: • Biocompatibility assays w/o animals (ISO) Artificial skin Irritation © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 32
  33. 33. Technological approach • Applications: • In vitro diag and Research • Biomarker • Drug kinetic • Pathogen reaction © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 33
  34. 34. Biotechnolgies & Bioprocess • Applications: • Biomolecule production in 3D • Machine producers © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 34
  35. 35. Food & Agriculture • Applications: • New food process? Focus on food player with Life Science approach: biomaterial ( e.g. Tissue engineering) © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 35
  36. 36. Bioprinting • Where beginning R&D? © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 36
  37. 37. Tissue engineering basics • Lamarck (1744–1829): La fonction crée l’organe (The function creates the organ). © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 37
  38. 38. Tissue engineering basics • Lamarck (1744–1829): the function creates the organ. daylife example: tissue reacts to device « 2nd skin » development © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 38
  39. 39. Tissue engineering basics • One scaffold can be enough Tube with structure mimicking vascular matrix Rat implantation Cell infiltration  differentiation  scaffold disapear  tissue restorated © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 39
  40. 40. Tissue engineering basics Scaffolds + stem cells + growth factors = work better Artificial kidney tissue Artificial heart tissue (Taylor, Minnesota, 2009) Scaffolds come from animal washed for cells © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 40
  41. 41. 3D Bioprinting solutions Personalized scaffolds  incubation with stem cells IPL, UGent, … © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 41
  42. 42. 3D Bioprinting solutions Nanostructure for fluidic, cell interaction, scaffold,… 2PP (two photon Nanoscribe polymerisation) Very small devices © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 42
  43. 43. 3D Bioprinting solutions Industrial machines Personalized scaffolds  incubation with stem cells (and cell printing) EnvisionTech, GESIM, Regenovo (China)… © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 43
  44. 44. 3D Bioprinting solutions Personalized scaffolds + stem cells  incubation © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 44
  45. 45. Bioprinting players in the world • Keyplayers outside Europe • Dr. Shinya Yamanaka (JPUS): stem cells • Dr. Anthony Atala (US, Boston) • Wake Forest University (US, North Carolina) • ACES (Australia) biopen • China © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 45
  46. 46. Bioprinting players in Europe – few © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 46
  47. 47. « Medical Additive Manufacturing & Rapid Prototyping » « Sirris » © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 47
  48. 48. Sirris Additive Manufacturing: Contact Carsten ENGEL, Ir, MBA Grégory NOLENS, PhD Department of Additive Manufacturing Department of Additive Manufacturing Mail: carsten.engel@sirris.be Mobile: +32 498 91 94 50 Skype: Carsten-Engel Mail: gregory.nolens@sirris.be Mobile: +32 498 91 94 75 Skype: gnolens SIRRIS Rue Auguste Piccard, 20 B-6041 GOSSELIES BELGIUM http://www.sirris.be SIRRIS Rue Auguste Piccard, 20 B-6041 GOSSELIES BELGIUM http://www.sirris.be © sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014 CENG 48

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