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Inside3DPrinting_DaveFlynn
This document summarizes David Flynn's presentation on Materialise's engineering applications in human anatomy. Materialise is a company established in 1990 in Belgium that uses additive manufacturing to provide medical services and software. Their Mimics Innovation Suite uses imaging data to construct 3D anatomical models for medical visualization, surgical planning, and custom implants. Case studies presented applications in modeling complex anatomy for surgery, 3D printing surgical guides for procedures like knee replacements, and designing custom implants tailored to individual patient anatomy.
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- 1. Engineering on HumanAnatomy 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. About Materialise • Company •Established 1990 • Leuven, Belgium • ±1000 employees • Worldwide presence 2
- 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. Diversity means strength Courtesyof TotalSim Ltd. Courtesy of IDEE / Maastricht Instrument 4
- 5. Mimics Innovation Suite: OurTotal 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. Medical scanner (CT/MR/US) Yourown PC or laptop Mimics
- 7. 3-matic ® • Designand meshing software ideally suited for use with anatomical data 7 Design: custom cranial plate Meshing: vertebrae remeshing
- 8. Case Studies •Visual andDiagnostic Aids: • Medical Models • Surgical Intervention •Engineering Functionality: • Surgical Guides • Patient Specific Implants 8
- 9. MEDICAL MODELS AS VISUALIZATIONAND DIAGNOSTIC AIDS 9
- 10. Medical Models • Separateconjoined 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. Medical Models • 3Dultrasound with tomographic output 11 Jorge Santos et al. 2009, Royal College of Art, UK
- 12. MEDICAL MODELS USEDFOR SURGICAL INTERVENTION 12
- 13. SURGICAL INTERVENTION CASE STUDY:AORTIC DISSECTION 13
- 14. Case Study: AorticDissection •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. Modeling from CTimages
- 16. Outcomes • No interventionpossible • 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. SURGICAL INTERVENTION CASE STUDY:CONGENITAL CARDIAC MALFORMATION 17
- 18. Case: Congenital CardiacMalformation • 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. How was itcreated? Emory University Hospital
- 20. SURGICAL GUIDES: TOTAL KNEEREPLACEMENT 20
- 21. Patient Specific Guides forTotal Knee Replacement Scan Patient Construct 3D models Plan the surgery Design & build guides Enter the OR
- 22. Scan Patient Construct 3D models Plan the surgery Design& build guides Enter the OR Patient Specific Guides for Total Knee Replacement
- 23. Scan Patient Construct 3D models Plan the surgery Design& build guides Enter the OR Patient Specific Guides for Total Knee Replacement
- 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. Scan Patient Construct 3D models Plan the surgery Design& build guides Enter the OR Patient Specific Guides for Total Knee Replacement
- 26.
- 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. Case presented byDaniel Buchbinder, MD DMD, Beth Israel New York CMF Software & Surgical Guides
- 29. Guide Benefits • Increasecollaboration 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. Guide Production • 5dedicated 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.
- 32. • Design in30 minutes • Design was watertight and ready to print • Model printed in Ti6Al4V with EBM (Arcam) Custom Implant Design- 3-matic®
- 33. Custom Implant Design •Cranio-Plate • Porosity Built In
- 34. Patient specific implantdesign • 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. Patient-Specific Acetabular CupImplant 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. Patient specific implantdesign using FEA • Model results • Manufacturing (selective laser melting) 36 Implant integrity Bone loading
- 37. Custom Implants– AcetabularCup • Custom Acetabulum Implant
- 38. Where do wego from here? • Future of healthcare is customization • Key to better patent care lies in patient specific solutions tailored to individual anatomy
- 39.