More Related Content Similar to Medical applications of Additive Manufacturing Technologies in general Similar to Medical applications of Additive Manufacturing Technologies in general (20) More from Carsten Engel (6) Medical applications of Additive Manufacturing Technologies in general1. The collective centre of the Belgian technology industry
le centre collectif de l’industrie technologique belge
2. Agenda
• Sirris – an overview
• Manufacturing of implants (past & current)
• Patient – custom manufacturing of implants (current & future)
• « Rapid Prototyping » & « Additive Manufacturing » technologies
• Future of bio-manufacturing
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 2
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3. Our centre
Federation Collective centre
for the technology industry of the technology industry
• Nonprofit organisation
• Industry owned
Mission
competitiveness of
“Increase the
companies of the Agoria sectors through
technological innovations”
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 3
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4. Our technological sectors
Aerospace Automotive Construction products
Contracting & Maintenance Electrical engineering
Industrial automation Mechatronical engineering
Information and communication technologies (ICT)
Metals & materials Metal processing Mounting & cranes
Plastics & composites Security & defence
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 4
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5. Local presence, near the companies
Ghent Leuven
Materials Engineering Mechatronics
Technology Coaching
Brussels Hasselt
Software Engineering & ICT Materials Engineering
Technology Coaching Production Technology
Liège
Charleroi Additive Manufacturing
Additive Manufacturing Materials Engineering
Bio-Manufacturing Platform Nanomaterials
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 5
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6. Additive Manufacturing Department (ADD)
Medical
Applications
Charleroi The Collective Centre of the Belgian Technology Industry
le centre collectif de l’industrie technologique belge
7. Agenda
• Sirris – an overview
• Manufacturing of implants (past & current)
• Patient – custom manufacturing of implants (current & future)
• « Rapid Prototyping » & « Additive Manufacturing » technologies
• Future of bio-manufacturing
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 7
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8. Implant manufacturing (current & past)
Case study: Femoral & Total hip implants
• Today : Mass fabrication of standard femoral implants (& others)
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 8
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9. Implant manufacturing (current & past)
Case study: Femoral & Total hip implants
• Today : Mass fabrication of standard femoral implants (& others)
[Société Royale Belge de Chirurgie Ortho et Traumato] [Critt MDTS 2008]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 9
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10. Implant manufacturing (current & past)
Current advanced pre-operative manufactured implants:
[Hôpital St-Margueritte – Marseille, France, Départementd’Orthopédie]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 10
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11. Implant manufacturing (current & past)
Current advanced pre-operative manufactured implants:
CT scan Rapid Prototyping model
Manual manufactured wax model Implant PMMA injection moulded
[Dr J. Poukens - UHasselt]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 11
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12. Agenda
• Sirris – an overview
• Manufacturing of implants (past & current)
• Patient – custom manufacturing of implants (current & future)
• « Rapid Prototyping » & « Additive Manufacturing » technologies
• Future of bio-manufacturing
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 12
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13. Benefits of Additive Manufacturing @ Medical field
• Evolution of medical imagery technology
=> Easy access to 3D world !
Need for custom implants !
Every human is different (anatomy)
Need of flexibility, complex structures and fast
response for surgery! Very small or even
standard (large) manufacturing series possible
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 13
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14. 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 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 14
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15. ADD capacities & competencies
Medical Additive Manufacturing Software:
• Materialise: Mimics
• Materialise: 3-matic
• Marcam: Autofab
• Able Software Corp: 3D Doctor
• Medicim: Maxilim
• ProEngineer
• New: Lenexa: Analyze
• New: Brisbane: Anatomics
• (…)
[Mimics & 3-matic - Materialise]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 15
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17. Rapid Prototyping / Tooling / Manufacturing
Process…
(…)
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 17
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18. Rapid Prototyping / Tooling / Manufacturing
Process…
3D CAD File
• Basic data :
Scan / 3D CAD files – STL
• Pre-treatment : 3D STL File
STL corrections, orientation, supports, 2D slicing
• Manufacturing :
Full automatic
Sliced File
• Post-treatment :
Cleaning, sand blasting, coating, finishing
Σ 2D layers
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 18
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19. Rapid Prototyping vs Additive Manufacturing
Rapid Prototyping Additive Manufacturing
• Stereolithography • Electron Beam Melting
• Bi-material 3D Printing • Selective Laser Melting
• 3D Printing of wax • Laser Cladding
• Selective Laser Sintering • Hybrids of Stereolithography
• 3D Printing of polymers / plaster
Functional
parts
Visual Final
parts parts
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 19
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20. Sirris ADD capacities & competencies
SIRRIS – World 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)
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 20
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21. The utility of Rapid Prototyping / Manufacturing in
the medical field
Trends in biocompatible materials used in Rapid Prototyping / Manufacturing:
Metals: Polymers:
• Titanium (Ti6Al4V) • PTFE (Polytetrafluoroethylene)
• Stainless steel • PMMA (Polymethyl methaacrylate)
• Shape memory alloys (Ni-Ti) – in research • PE (Polyethylene)
• Noble materials (Gold) • … others, too but not implantable
• …
Others:
Ceramics:
• Hydrogels
• Hydroxyapatite (HAP) • Human cells
• Zirconia
• Tricalcium phosphate (TCP)
• Alumine
• …
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 21
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22. The utility of Rapid Prototyping / Manufacturing in
the medical field
Leading applications:
• Pre-surgical planning:
[Arcam & Objet technology]
• Custom implant manufacture
• Physician to physician communication
• Powerful patient presentation tool [Z. Corp Medical Modeling Solutions]
• Medical student/resident education
• 3D Surface Scanning/Custom Prosthesis Design
[Objet Connex Eden 500]
[Z. Corp Medical Modeling Solutions]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 22
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23. 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 2010 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 23
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24. The utility of Rapid Prototyping / Manufacturing in
the medical field
Leading applications:
• Pre-surgical planning advantages:
• Significantly reduces O.R. time
• Lowers cost
• Reduces O.R. team fatigue
• Enhances patient outcomes
• Reduces “re-do” procedures
• Minimizes size of incisions [Z. Corp Medical Modeling Solutions]
• Speeds recovery time
• Improves anatomical alignment
• Enables multiple procedure rehearsals
[Case study: The Alfred Hospital, Melbourne, Australia]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 24
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25. Towards newly designed implants
Case study: Femoral & Total hip implants
• Today: Custom-fit femoral implants
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 25
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26. 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 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 26
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27. Medical Field: CASE STUDIES @ SIRRIS
Leading applications:
• Custom Prosthesis Design
• Complex parts manufacturing
[Sirris ADD] [Sirris ADD]
[Sirris ADD]
[Sirris ADD] [Sirris ADD]
[Sirris ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 27
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28. Medical Field: CASE STUDIES @ SIRRIS
Spinal & CMF case studies in HAP/TCP:
• Porous scaffolds in Hydroxyapatite Ca5(PO4)3(OH)
• Diameter ~= 10mm
• Macro-porosity ~= 0,5mm
• Tests various scaffold structures for bone integration
• In vivo testing (rabbits)
• Machine: Optoform
• Field: Maxillofacial Surgery in France (Client is confidential)
• Production of 1000 parts / month (total of 10.000 in 2011)
[Sirris ADD]
[Sirris ADD] [Sirris ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 28
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29. Medical Field: CASE STUDIES @ SIRRIS
Project: “Optobio”
Client: Osseomatrix (Dr Nimal)
• Porous & dense orbital implant in Hydroxyapatite Ca5(PO4)3(OH)
1,4mm
0,5mm
[Sirris ADD] [Sirris ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 29
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30. Medical Field: CASE STUDIES @ SIRRIS
Project: “Optobio”
Client: Osseomatrix (Dr Nimal)
[Sirris ADD] [Sirris ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 30
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31. Medical Field: CASE STUDIES @ SIRRIS
Project: Surgical Cutting Template
• CHU Reims (France)
• 100% dense Ti6Al4V Titanium
• Build time: 6 hours
• Weight: 75g
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Oral and Maxillofacial Plastic Surgery
[Sirris ADD]
Project: Surgical Cutting Template
• UCL-St Luc (Belgium)
• 100% dense Ti6Al4V Titanium
• Build time: 4 hours
• Weight: 25g
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Oral and Maxillofacial Plastic Surgery
[Sirris ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 31
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32. Medical Field: CASE STUDIES @ SIRRIS
Demonstration part: Knee implant
• 100% dense Ti6Al4V Titanium with porous Ti6Al4V scaffolds
• Build time: 8 hours
• Weight: 170g
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Knee implant orthopaedics
[Sirris ADD]
Demonstration part: Craniofacial implant
• Sirris (Belgium)
• Porous Ti6Al4V Titanium scaffold implant
• Polyamide skull on Z-Corp machine
• Machine: Arcam A2 (Electron Beam Melting)
• Field: Cranio-plastic surgery
[Sirris ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 32
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33. Medical Field: CASE STUDIES @ SIRRIS
Project: “HEROL” (2002: 4 years)
• Goals:
• Enhance the performances of CMF surgery, implant
placement accuracy
• Enlarge the fields of applications through AM technologies
• Processing & editing of 2D CT-Scans
• Decrease operating time
• Simplify complex operations
Example of end-user: A.C.M. Implants (Belgium)
• 3D reconstruction of the hip
• Decision & pre-operation planning for surgeons
• Plaster cast on Z-Corp machine with post finishing
• Collaboration: Sirris; UCL; CERISIC
• Results: creation of spin-off: « CenTIS » (www.centis.be)
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 33
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34. Medical Field: CASE STUDIES @ SIRRIS
Project: “Nanoker” (2005: 4 years) large scaled European project
• Goals:
• Development of nanomaterials for improved tribological
applications
• Fabrication on the Optoform machine
• Fields of applications : Knee and hip implants, dental
applications
• Results:
• Development of a very reactive Alumina paste containing 8%
of Zirconia nano powders [Sirris ADD]
• Partners (25): www.nanoker-society.org
[Sirris ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 34
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35. Medical Field: CASE STUDIES @ SIRRIS
Project: “BIOFACT” (2007 - 2013)
• Goals:
• Design, fabrication and establishment of an external feed
prosthesis controlled by neuronal signals (EEG instead of EMG)
• Creation of the “Biomanufacturing platform” in Charleroi
• Thermodynamic control, calculation and validation of the EBM
process
• Technologies involved: Connex Eden 500, Arcam A2
• Partners: Sirris; CENAERO; UMONS, CETTIC, ULB
• Results: creation of spin-off: « Human Waves » (soon)
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 35
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36. Medical Field: CASE STUDIES in the world
Replacement of Temporomandibular joints
• Reference: Dr. Jules Poukens, Cranio-maxillofacial Surgeon and Lecturer University Hasselt
• Custom fit Titanium implant with surface porosity: allowing tissue ingrowth & stability
• Polyethylene part fixed to the Titanium implant: flat functional surface & providing a centric relation
posititon for the condyle
• Stereolithographic model for validation
[Dr J. Poukens - UHasselt]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 36
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37. Medical Field: CASE STUDIES in the world
Replacement of Temporomandibular joints
[Dr J. Poukens - UHasselt]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 37
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38. Medical Field: CASE STUDIES in the world
[Dr J. Poukens - UHasselt]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 38
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39. Agenda
• Sirris – an overview
• Manufacturing of implants (past & current)
• Patient – custom manufacturing of implants (current & future)
• « Rapid Prototyping » & « Additive Manufacturing » technologies
• Future of bio-manufacturing
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 39
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40. Towards newly designed implants
[Butscher A., et al., Structural and material approaches to bone tissue engineering in powder-based three-dimensional printing. Acta Biomater (2010)]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 40
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41. Towards newly designed implants
3,5
3
2,5
2
Ceramics
1,5 Metals
Polymers
1
0,5
0
Elasticity Yield strength Resilience Hardness In vivo Bone response
(Young's resistance to implant
Modulus) (phys.-chem.) material
[Black J., et al., Orthopaedic biomaterials in research and practice. Churchill Livingstone. New York: P.394, 1988]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 41
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42. Towards newly designed implants
Ti6Al4V: E(GPa) = 110 !
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 42
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43. Towards newly designed implants
Case study: Femoral & Total hip implants
• Tomorrow: Custom-fit femoral implants & adapted Young’s modulus
• Patient custom-fit implants
• Better distribution of the stresses
• Reducing stress-shielding
• Reducing micro-motion between bone & sinkage
• Surface roughness for strong fixation
• Hydroxyapatite coating eased up
• Complex biodegradable scaffolds combining HAP & βTCP
+ +
[Sirris - ADD]
[Sirris - ADD]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 43
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44. Towards newly designed implants
CT-scan data
Data processing & exporting
3D cellular microstructure Lattice structures
3D modeling – CAD & FEA
Custom fit & dense implant + 3D microstructure
STL file
Implant manufacturing
Milling Post processing HAP/TCP coating [Butscher A et al.]
Sterelization Surgeon validation
&
Surgery Control by experts
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 44
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45. Towards newly designed implants
Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)
Distal Metacarpal bone
part
Trapezium
(Wirst)
Proximal
part
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 45
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46. Towards newly designed implants
Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 46
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47. The future of bio-manufacturing…not so far away!
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 47
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48. Sirris Additive Manufacturing: Contact
Carsten ENGEL
R&D Biomedical Engineer
Mail: carsten.engel@sirris.be
Mobile: +32 498 91 94 50
Skype: Carsten-Engel
SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 25/11/2011 48
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