One of the hottest applications for 3D printing / Additive Manufacturing is medical. Dental appliances, surgical models, prosthetic prototypes and some end use versions, skeletal support, and other applications are possible because of the unique capabilities of 3D printers. In this webinar we will hear from three vendors with applications in this field; their challenges, their successes, and what they’ve learned about working with 3D printers in this industry. In this webinar you will learn: The best medical applications for 3D printing today Material considerations, including mechanical and thermal properties and biocompatibility. Design tips View the recording: http://www.designworldonline.com/upcoming-live-webinar-tips-for-better-3d-printing-for-medical-applications/

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Tips for 3D printing for
medical applications

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Thank you to our sponsor

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q This webinar will be available afterwards at
www.designworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #DWwebinar
Before We Start

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Leslie Langnau
Design World
Moderator
John Murray
President & CEO
Concept Laser, Inc.
Katie Weimer
Vice President
of Medical Devices
3D Systems
Tips for 3D printing for medical applications
Gil Robinson
Senior Applications
Engineer
Stratasys, Verticle
Solutions
Meet your presenters…

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Ka#e
Weimer,
MS
Vice
President,
Medical
Devices
August
26,
2015
TIPS
FOR
BETTER
3D
PRINTING
OF
MEDICAL
APPLICATIONS

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Chuck Hull
Inventor of 3D Printing
First 3D Printed Part
March 9, 1983

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February 5, 2015

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Material
Extrusion:
“An
AM
process
in
which
material
is
selecMvely
dispensed
through
a
nozzle
or
orifice”
Material
Je7ng:
“An
AM
process
in
which
droplets
of
build
material
are
selecMvely
deposited”
Stereolithography:
(vat
photopolymerizaMon)
“An
AM
process
in
which
liquid
photopolymer
is
selecMvely
cured
by
a
light
acMvated
polymerizaMon
Powder
Fusion:
“An
AM
process
in
which
thermal
energy
selecMvely
fuses
regions
of
a
powder
bed”
Standard
Terminology
for
AddiMve
Manufacturing
Technologies
(ASTM
F2792)

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Direct
Metal
PrinMng
(DMP)
SelecMve
Laser
Sintering
(SLS)
Stereolithography
(SLA)
Fused
DeposiMon
Modeling
(FDM)
ColorJet
PrinMng
(CJP)
MulMJet
PrinMng
(MJP)

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Di Prima, Ma,hew. Presentation: “FDA Technical Perspective on Additive Manufacturing” Additive Manufacturing for Medical. Boston July 2015
• 70+
AM
devices
cleared
through
the
510(k)
pathway
• AM
devices
regulated
through
the
same
pathways
as
non-­‐AM
devices
• Significant
increase
in
510(k)
cleared
devices
2011-­‐2012
• Majority
of
510(k)
clearances
for
orthopedics
applicaMons
FDA Status of 3DP in Medical Devices

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Common Applications

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Medical Devices are Regulated J
Any
3D
Printed
Medical
Device
has
to
go
through
same
‘scope
of
a
regulated
product’
as
non
3D
printed
medical
devices.
(even 3D printed ones)
Receipt of
materials
Design of
product
Premarket
testing and
activities
Manufactu-
ring of
product
Final
inspection/
QC of
product
Shipment
of product

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Class I

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Class II

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Class III

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What
were
some
challenges
you’ve
encountered
in
using
3D
prinMng
in
a
medical
applicaMon?

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Its
not
just
about
the
3D
printer
anymore…
The Digital Thread

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We Had to Rethink Design
• Patient specific design is complex
• Software tools made to handle organic geometries are key

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Haptic Design

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Conformal Design

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Consistency in Manufacturing
• Raw material control
• Calibration
• Environmental controls
(temperature, humidity)
• Part support
• Post Processing
(removal of liquid polymer /
excess powder, light curing,
stress relief / HIP for metals)

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Build Orientation of Parts

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Why additive for implants?
• Porous, porous, porous
• Bone ingrowth provides both
better initial and long-term
stability
• Properties close to human bone
(avoid stress shielding)
• With additive methods we create
the solid and porous in one
integrated step
• Complexity is free
• Ideally suited for patient specific

25. #DWwebinar Di Prima, Ma,hew. Presentation: “FDA Technical Perspective on Additive Manufacturing” Additive Manufacturing for Medical. Boston July 2015
Unit Cells of Design
• Design Strongly effects
performance
• Density: overall porosity,
pore size, strut size
• Design is based on unit
cell size and shape

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With 3D printing, how will design
of medical devices change?
• THINK DIFFERENTLY – you are
no longer designing based on the confines
of a traditional manufacturing
• Conformal design for the human body will
continue to grow
• The design cycle from idea to product
continues to improve Swedish firm Gassling

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THANK
YOU!
kaMe.weimer@3dsystems.com

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3DP IM – What is it?
3DP IM – Where does it fit?
3DP IM – When to Use it?
3DP IM – Customer Stories
3DP IM – How to Use it?
01
02
03
04
05

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http://www.meddeviceonline.com/doc/3d-printed-
injection-molding-the-future-of-rapid-prototyping-0001
• Production grade parts:
available for verification and
validation testing
• Accelerate development: 90%
+ time savings
• Highly cost effective: save
60-75% on tooling

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.Medical
John D. Murray
President & CEO
Concept Laser Inc.
ImagescourtesyofConceptLaser

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.1997 – Development of Laser Melting
Technology
.1999 – First patent for stochastic exposure
.2000 - Concept Laser GmbH
.2002 – First machine delivery for metal
3D Printing
.2003 – Sales, Marketing and Service
structure implemented
.2012 - Concept Laser, Ningbo (China)
.2014 - Concept Laser Inc., Dallas (USA)
Background
www.conceptlaserinc.com

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. Machine type for every application
. Use of Rapid Prototyping up to the
integration in the production environment
. Build envelope from small (50 x 50 x 70)
to large (800 x 400 x 500) available
. Laser power of 100 watts up to multi laser
solutions with 2 x 1 kW
Machine Portfolio
www.conceptlaserinc.com

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Materials
.20s: Stainless steels
.30s: Aluminium alloys
.40s: Titanium alloys
.50s: Tool steels for plastic injection molding
.60s: Tool steels for aluminum die-casting
.70s: Tool steels for mechanical engineering
.80s: Copper alloys
.90s: Stainless hot-work steels
.100s: Nickel-based alloys
.110s: Cobalt chrome
.Special and other alloys available upon request
www.conceptlaserinc.com

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Medical Mold Aerospace
Automotive Jewelry Dental
Industries
www.conceptlaserinc.com

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LaserCUSING® Process
ImagecourtesyofConceptLaser
www.conceptlaserinc.com

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Material-Efficient
Waste with CNC Machining
Conventional Machining
(CNC material)
Material need with
additive manufacturing
Waste with additive
manufacturing
Metal Additive Manufacturing Process
ImagecourtesyofConceptLaser
www.conceptlaserinc.com
with metal additive manufacturing
CNC machined bracket
CNC Process
Additively manufactured
Bracket with optimized design

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In-Situ Process Monitoring
with QMmeltpool
. System is integrated into the optical path
. Process is monitored by camera systems
. Real-Time In-Situ monitoring possible
. Highest resolution
. Very high detection frequency 10kHz
www.conceptlaserinc.com

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QM system: QMmeltpool
Part no. 1: NOT OK
Part no. 30: OK
Part no. 30
Part no. 1
www.conceptlaserinc.com

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Specific solutions for medical applications:
o Trauma
o Spine
o CFM (craniofacial microsomia)
Advantages:
o Manufacturing of customized biocompatible
implants or prosthesis with microcellular
structure
o Manufacturing of bone-foams with bioanalog
structure to use as bone substitute material
o Manufacturing of unique or complex serial
implants or instruments
o CE-certified materials for medical applications
Medical
www.conceptlaserinc.com

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Tsunami Medical
Design for AM Component Preparation Component Assembling
Component Laser Welding Shine Polishing
www.conceptlaserinc.com

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Hip stem implant
Manufactured on M2 cusing / prototype manufactured
from the material CL 41TI (TiAl6V4 ELI) /
LaserCUSING allows the manufacture of implants with
unique geometric features, which in turn make new
features or functional integration in implants possible.
These include macroporous surface structures for an
improved bone ingrowth into the implant and volume
structures to adopt the stiffness of the implant to the
bone.
Implant with metal bone „foam“
• Lattice structure to allow bone ingrowth
• Only possible with additive technology
• Mass production or customized products
Mugeto®
www.conceptlaserinc.com

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Implants and Instruments

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Leslie Langnau
Moderator
Design World
llangnau@wtwhmedia.com
@DW_3Dprinting
Katie Weiner
Vice President of Medical Devices
3D Systems
Katie.Weimer@3dsystems.com
Questions?
John Murray
President & CEO
Concept Laser, Inc.
J.Murray@conceptlaserinc.com
Gil Robinson
Senior Applications Engineer
Stratasys, Vertical Solutions
Gil.Robinson@Stratasys.com
Tips for 3D printing for medical applications

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Thank You
q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
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