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Additive Manufacturing - Powder Considerations Rapid Fire - OMTEC 2018

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Understanding the Cost Drivers of Metal Powders: The true costs associated with additive manufacturing processes are often not well understood. To fully grasp the actual manufacturing costs, and therefore the economic viability of AM, each aspect of the entire chain needs to be well understood and controlled. This presentation uncovers the costs and main cost controls surrounding the metal powders used in AM.

Practical Implementation of PEKK Additively Manufactured Orthopaedic Devices: learn how much of the discussion surrounding implementation of additive manufacturing has been focused more on the machine and less on the material and process system, resulting in new structures that then needed to be considered for applications and validated for incorporation into new products.

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Additive Manufacturing - Powder Considerations Rapid Fire - OMTEC 2018

  1. 1. CONTROLLING (POWDER) COSTS IN ADDITIVE MANUFACTURING Eric Bono, Carpenter Technology Corp.
  2. 2. World’s largest supplier of gas atomized powders 2 CENTRAL & SOUTH AMERICA EUROPE NORTH AMERICA Manufacturing Specialty stainless & tool steel powder Nickel, cobalt, steel alloys powder Ultrafine powder Reading, PA Powder-to-part AM Technology Center Superalloy powder ASIA / APAC Titanium powder AM wire products (Ti, Ni, Fe alloys) Sales office
  3. 3. AM Cost Structure 3 We ALL need to better understand the true underlying costs associated with the entire AM supply chain: • Machine purchase price (and depreciation) • Powder costs • Energy • Training • Post processing • Quality • On and on…
  4. 4. AM Cost Structure 4 We ALL need to better understand the true underlying costs associated with the entire AM supply chain: • Machine purchase price (and depreciation) • Powder costs • Energy • Training • Post processing • Quality • On and on…
  5. 5. Labor EquipmentMaterial Major AM Cost Drivers 5
  6. 6. Labor 20% Equipment 60% Material 20% Major AM Cost Drivers 6
  7. 7. Labor 20% Equipment 60% Material 20% Major AM Cost Drivers 7 Why so much focus here???
  8. 8. Why the focus on powder costs? 8 • Easy to measure line item • Easy to put pressure on suppliers • Most visible system component • (Inaccurately) seen as a high-margin item
  9. 9. Metal Powder Cost Drivers 9 • Powder chemistry requirements • Particle Size Distribution (PSD)
  10. 10. Metal Powder Cost Drivers 10 • Powder chemistry requirements - Custom alloys (first pound is a killer) - Sourcing restriction (domestic vs. foreign) - Overly tight controls
  11. 11. Metal Powder Cost Drivers 11 • Powder chemistry requirements - Custom alloys (first pound is a killer) - Sourcing restriction (domestic vs. foreign) - Overly tight controls We need oxygen between 0.145% & 0.150%
  12. 12. Metal Powder Cost Drivers – PSD 12
  13. 13. Metal Powder Cost Drivers – PSD 13
  14. 14. Metal Powder Cost Drivers – PSD 14 Surface Enh. AdditiveMfg. MIM
  15. 15. Metal Powder Cost Drivers – PSD 15 L-PBF Spec Size Range (microns) Company A -45 mm Company B 10 - 45 mm Company C 15 - 45 mm Company D -53 mm Company E 10 - 53 mm Company F 15 - 53 mm Company G 20 - 63 mm Company H 25 - 63 mm Company I <5 mm
  16. 16. Metal Powder Cost Drivers – PSD 16 L-PBF Spec Size Range (microns) Company A -45 mm Company B 10 - 45 mm Company C 15 - 45 mm Company D -53 mm Company E 10 - 53 mm Company F 15 - 53 mm Company G 20 - 63 mm Company H 25 - 63 mm Company I <5 mm A typical human hair is 100 mm!
  17. 17. We are working hard to harmonize PSDs 17
  18. 18. PSD Games That We Must Play 18 0 500 mm Ideal World Laser Ebeam HIP 53 106
  19. 19. PSD Games That We Must Play 19 500 mm Harsh Reality Laser Ebeam HIP 45, 50, 53, 630, 10, 15, 20, 25
  20. 20. Metal Powder Cost Drivers 21 Overly tight PSD requirements Powder 1 Powder 2 PSD d10 = 10-12 mm d50 = 16-20 mm d90 = 44-47 mm 15-53 mm, 5% tolerance Cost 1.4X X
  21. 21. Why use Additive 22 • Print geometries that improve osteointegration • Control mechanical properties – minimize stress shielding • Patient-specific implants
  22. 22. And along comes additive … 23
  23. 23. And along comes additive … 24 Contrary to what many are saying … AM is NOT always the best tool for the job.
  24. 24. Give me a ring with any questions – Eric Bono – Carpenter Technology Corp. – Phone: 412.260.8048 – Email: ebono@cartech.com 20
  25. 25. Biomedical 21st CENTURY ENABLING TECHNOLOGIES Properties and Applications of PEKK in Orthopaedics OMTEC June 13, 2018 OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL Oxford Performance Materials Scott DeFelice Chairman and CEO Oxford Performance Materials
  26. 26. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL What is PEKK? High Performance • Medical • Aerospace • Defense • High Temperature Industrial • Oil Field/Down Hole • High Performance Automotive Engineering • Sporting Goods • Orthotic/Prosthetic • General Industrial • Lawn & Garden Commodity • Infrastructure • Packaging • Increasing Temperature, Tolerance, & Physical Performance OPM’s OXPEKK® formulation has exceptional physical properties: • Superior strength • Excellent chemical resistance • Tailored electrical properties • -300°F to 300°F applications PEKK 2
  27. 27. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL 3 • PEKK polymer is shown to be safe for long term human implantation in sites with primary bone/tissue contact • Extensive testing in accordance with ISO 10993 standards Genotoxicity (ISO 10993-3) Cytotoxicity & Neurotoxicity (ISO 10993-5) Implantation (ISO 10993-6) Irritation and Sensitization (ISO 10993-10) Systemic Toxicity (ISO 10993-11) Chemical Characterization (ISO 10993-18)
  28. 28. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL 4 PEEK PEKK Superior Fiber Adhesion Enables Superior Performance PEKK vs. PEEK Thermal: • Higher glass transition Co-Polymer System: • Variable isomer ratio (T/I, 60/40 or 80/20) • Control of kinetics Mechanical: • Substantially higher compressive strength & increases in most other properties Lower Molded In Stress: • Concentricity • Flatness Kinetics: • Slower crystallization kinetics leads to lower molded In stress • Reduces the need for secondary annealing operations Non Sodium Based Catalyst: • Low ionic extractable content (high purity) Adhesion: • Superior adhesion performance Adhesion & Wetting • PEKK chemistry highly suitable for bonding • Ability to adhere to itself • Enabling mechanical performance
  29. 29. 3D Printed PEKK Counters Antibiotics Abuse/Overuse OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL 5
  30. 30. Osseointegration In an ovine model, histological review of TETRAfuse™ 3D Technology samples showed deeper implant osseointegration and more notable trabecular bone ingrowth (Table 1) compared to PEEK and titanium (Ti) coated PEEK.2 TABLE 1: Results from TETRAfuse Ovine Study TETRAfuse is the trademark of RTI Surgical, Inc. for its use of OPM’s OsteoFab® Technology. All data above are the property of RTI Surgical, Inc. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL 6
  31. 31. OsteoFab® 3D Printed Medical Devices “Debulking” of implant from powder bed OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL Selective laser sintering Multiple units processed in one build Digital build preparation Dimensional and visual inspection Shipment to healthcare facility Implantation 7
  32. 32. 8 Titanium ✓ Complex designs ✓ Biologic fixation ✓ Radiolucency ✓ Bone-like mechanics PEEK OsteoFab® Technology ✓ Bone-like mechanics ✓ Radiolucency ✓ Biologic fixation ✓ Antibacterial properties And with Additive Manufacturing: ✓ Reduced Cost ✓ Manufacturing flexibility ✓ Complexity - new solutions OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL PEKK: The Perfect Combination For Implantation
  33. 33. Case Study: Right Frontal Sphenoid Parietal Orbital Implant Hôpital Notre-Dame, Montreal, Québec, Canada OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL 9
  34. 34. Disruptive Attributes 3D Printed PEKK Technology: Disruptive in Medicine OsteoFab® Technology Fixation by Bone Imaging Friendly Promotes Bone Formation Infection Resistant Durable Biocompatible Precise Fit Load bearing Material and Manufacture • Low cost + complexity Enables New Functionality • Bone ingrowth • Tx Delivery Changes Treatment Approach • Elevated response • New devices Streamlined Development • Regulatory framework 10 OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
  35. 35. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL Cranial Facial Ligament Repair Shoulder Reconstruction Spine Cardiothoracic Reconstruction Knee Infection Knee Replacement Osteotomy Wedge Small bones Foot Small bones Hand Ankle Reconstruction Long Bone Defects Mandibular Reconstruction Certain devices and concepts above are under development and have not been cleared by the FDA OsteoFab® Technology Platform Going Forward: A Platform for Accelerated Device Development 11

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