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le centre collectif de l’industrie technologique belge
The collective centre of the Belgian technology industry
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
2
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Our centre
Federation for the technology industry
Collective centreof the technology industry
• Nonprofit organisation
25/11/2011 3
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• Nonprofit organisation• Industry owned
“Increase the competitiveness of
companies of the Agoria sectors through
technological innovations”
Mission
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Our technological sectors
Aerospace Automotive Construction products
25/11/2011 4© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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Contracting & Maintenance Electrical engineering
Industrial automation Mechatronical engineering
Information and communication technologies (ICT)
Metals & materials Metal processing Mounting & cranes
Plastics & composites Security & defence
Local presence, near the companies
LeuvenMechatronics
Technology Coaching
HasseltBrussels
GhentMaterials Engineering
25/11/2011 5
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HasseltMaterials Engineering
Production Technology
CharleroiAdditive ManufacturingBio-Manufacturing Platform
BrusselsSoftware Engineering & ICTTechnology Coaching
LiègeAdditive ManufacturingMaterials Engineering
Nanomaterials
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Additive Manufacturing Department (ADD)
le centre collectif de l’industrie technologique belgeThe Collective Centre of the Belgian Technology Industry
Medical Applications
Charleroi
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
7
CENG
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Implant manufacturing (current & past)
Case study: Femoral & Total hip implants
• Today : Mass fabrication of standard femoral implants (& others)
25/11/2011 8
CENG
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Implant manufacturing (current & past)
Case study: Femoral & Total hip implants
• Today : Mass fabrication of standard femoral implants (& others)
25/11/2011 9
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[Société Royale Belge de Chirurgie Ortho et Traumato] [Critt MDTS 2008]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Current advanced pre-operative manufactured implants:
Implant manufacturing (current & past)
25/11/2011 10
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[Hôpital St-Margueritte – Marseille, France, Départementd’Orthopédie]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Current advanced pre-operative manufactured implants:
CT scan Rapid Prototyping model
Implant manufacturing (current & past)
25/11/2011 11
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Manual manufactured wax model Implant PMMA injection moulded
[Dr J. Poukens - UHasselt]
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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
12
CENG
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
• Evolution of medical imagery technology
=> Easy access to 3D world !
Need for custom implants !
Benefits of Additive Manufacturing @ Medical field
13
Need of flexibility, complex structures and fast
response for surgery! Very small or even
standard (large) manufacturing series possible
Every human is different (anatomy)
CENG
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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
The utility of Additive Manufacturing technologies
in the medical field
25/11/2011 14
• Surgery• Follow up
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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[Sirris ADD]
[Sirris ADD][Sirris ADD]
Medical Additive Manufacturing Software:
ADD capacities & competencies
• Materialise: Mimics• Materialise: 3-matic• Marcam: Autofab• Able Software Corp: 3D Doctor• Medicim: Maxilim
ProEngineer
15
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
• ProEngineer• New: Lenexa: Analyze• New: Brisbane: Anatomics• (…)
[Mimics & 3-matic - Materialise]
Subtractive technologies...
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 16
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Rapid Prototyping / Tooling / Manufacturing
Process…
(…)
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 17
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Rapid Prototyping / Tooling / Manufacturing
Process…
• Basic data :
Scan / 3D CAD files – STL
• Pre-treatment :
STL corrections, orientation, supports, 2D slicing
3D CAD File
3D STL File
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be | 18
STL corrections, orientation, supports, 2D slicing
• Manufacturing :
Full automatic
• Post-treatment :
Cleaning, sand blasting, coating, finishing
CENG
Σ 2D layers
Sliced File
Rapid Prototyping
• Stereolithography
• Bi-material 3D Printing
• 3D Printing of wax
• Selective Laser Sintering
• 3D Printing of polymers / plaster
Rapid Prototyping vs Additive Manufacturing
Additive Manufacturing
• Electron Beam Melting
• Selective Laser Melting
• Laser Cladding
• Hybrids of Stereolithography
19
• 3D Printing of polymers / plaster
CENG
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Functionalparts
Final parts
Visual parts
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)
Sirris ADD capacities & competencies
20
• 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)
CENG
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
The utility of Rapid Prototyping / Manufacturing in
the medical field
Trends in biocompatible materials used in Rapid Prototyping / Manufacturing:
Metals:
• Titanium (Ti6Al4V)• Stainless steel• Shape memory alloys (Ni-Ti) – in research• Noble materials (Gold)
Polymers:
• PTFE (Polytetrafluoroethylene)• PMMA (Polymethyl methaacrylate)• PE (Polyethylene)• … others, too but not implantable
25/11/2011 21
• Noble materials (Gold)• …
Ceramics:
• Hydroxyapatite (HAP)• Zirconia• Tricalcium phosphate (TCP)• Alumine• …
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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• … others, too but not implantable
Others:
• Hydrogels• Human cells
The utility of Rapid Prototyping / Manufacturing in
the medical field
Leading applications:
• Pre-surgical planning:
• Custom implant manufacture[Arcam & Objet technology]
25/11/2011 22
• Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
• 3D Surface Scanning/Custom Prosthesis Design
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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[Z. Corp Medical Modeling Solutions]
[Z. Corp Medical Modeling Solutions]
[Objet Connex Eden 500]
Leading applications:
• Pre-surgical planning:
• Implant pre-contouring• Screw trajectory• Screw selection/location• Instrument selection• Technique rehearsal
“No matter how good our 3-D graphics are, there isnothing like a model in your hands . . .”
The utility of Rapid Prototyping / Manufacturing in
the medical field
25/11/2011 23© sirris 2010 Charleroi | www.sirris.be | info@sirris.be |
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[Objet]
[Objet]
[Objet Connex Eden 500]
[Objet]
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
The utility of Rapid Prototyping / Manufacturing in
the medical field
25/11/2011 24
• Reduces “re-do” procedures• Minimizes size of incisions• Speeds recovery time• Improves anatomical alignment• Enables multiple procedure rehearsals
© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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[Z. Corp Medical Modeling Solutions]
[Case study: The Alfred Hospital, Melbourne, Australia]
Towards newly designed implants
Case study: Femoral & Total hip implants
• Today: Custom-fit femoral implants
25© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
Medical Field: CASE STUDIES @ SIRRIS
Leading applications:
• Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
25/11/2011 26© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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[Sirris ADD] [Sirris ADD]
[Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD]
Medical Field: CASE STUDIES @ SIRRIS
Leading applications:
• Custom Prosthesis Design
• Complex parts manufacturing
25/11/2011 27© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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[Sirris ADD] [Sirris ADD]
[Sirris ADD] [Sirris ADD]
[Sirris ADD]
[Sirris ADD]
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)
25/11/2011 28© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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• 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]
Medical Field: CASE STUDIES @ SIRRIS
Project: “Optobio”
Client: Osseomatrix (Dr Nimal)
• Porous & dense orbital implant in Hydroxyapatite Ca5(PO4)3(OH)
1,4mm
25/11/2011 29© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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[Sirris ADD] [Sirris ADD]
0,5mm
1,4mm
Medical Field: CASE STUDIES @ SIRRIS
Project: “Optobio”
Client: Osseomatrix (Dr Nimal)
25/11/2011 30© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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[Sirris ADD] [Sirris ADD]
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]
25/11/2011 31© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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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 ADD]
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]
25/11/2011 32© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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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 ADD]
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
33© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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• 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)
25/11/2011
Medical Field: CASE STUDIES @ SIRRIS
Project: “ Nanoker” (2005: 4 years) large scaled European project
• Goals:• Development of nanomaterials for improved tribologicalapplications• Fabrication on the Optoform machine• Fields of applications : Knee and hip implants, dental applications
34© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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• Results:• Development of a very reactive Alumina paste containing 8% of Zirconia nano powders
• Partners (25): www.nanoker-society.org
[Sirris ADD]
[Sirris ADD]
25/11/2011
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
35© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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• Technologies involved: Connex Eden 500, Arcam A2
• Partners: Sirris; CENAERO; UMONS, CETTIC, ULB
• Results: creation of spin-off: « Human Waves » (soon)
25/11/2011
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
36© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
[Dr J. Poukens - UHasselt]
Medical Field: CASE STUDIES in the world
Replacement of Temporomandibular joints
37© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
[Dr J. Poukens - UHasselt]
Medical Field: CASE STUDIES in the world
38© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
[Dr J. Poukens - UHasselt]
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
39
CENG
25/11/2011© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
Towards newly designed implants
25/11/2011 40© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
CENG
[Butscher A., et al., Structural and material approaches to bone tissue engineering in powder-based three-dimensional printing. Acta Biomater (2010)]
2
2,5
3
3,5
Ceramics
Towards newly designed implants
25/11/2011 41© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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0
0,5
1
1,5
Elasticity (Young's Modulus)
Yield strength Resilience Hardness In vivo resistance
(phys.-chem.)
Bone response to implant material
Metals
Polymers
[Black J., et al., Orthopaedic biomaterials in research and practice. Churchill Livingstone. New York: P.394, 1988]
Towards newly designed implants
42© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
Ti6Al4V: E(GPa) = 110 !
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
43© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
• Complex biodegradable scaffolds combining HAP & βTCP
+ +
[Sirris - ADD]
[Sirris - ADD]
CT-scan data
Data processing & exporting
3D modeling – CAD & FEA
Custom fit & dense implant 3D microstructure
3D cellular microstructure Lattice structures
+
Towards newly designed implants
25/11/2011 44© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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STL file
Implant manufacturing
Post processingMilling HAP/TCP coating
Sterelization
Surgery
Surgeon validation&
Control by experts
[Butscher A et al.]
Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)
Towards newly designed implants
45© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
Proximalpart
Distalpart
Metacarpal bone
Trapezium(Wirst)
Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)
Towards newly designed implants
46© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
The future of bio-manufacturing…not so far away!
47© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
Sirris Additive Manufacturing: Contact
Carsten ENGEL
R&D Biomedical Engineer
Mail: carsten.engel@sirris.beMobile: +32 498 91 94 50
48© sirris 2011 Charleroi | www.sirris.be | info@sirris.be |
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25/11/2011
Mobile: +32 498 91 94 50Skype: Carsten-Engel
SIRRISRue Auguste Piccard, 20B-6041 GOSSELIES BELGIUMhttp://www.sirris.be
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