Agenda - WeLLwell-livinglab.be/wp-content/uploads/2016/03/MSF...04/01/2016 5 04/01/2016 9 Next generation pre-operative manufactured implants: • Custom implant manufacture : •

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le centre collectif de l’industrie technologique belge

Additive Manufacturing

for medical applications

Advanced Manufacturing Department (ADM)

Agenda

Sirris - ADD

Additive Manufacturing Process

Benefits of Additive Manufacturing @ Medical field

The utility of Additive Manufacturing technologies in

the medical field

Medical Field: CASE STUDIES @ SIRRIS

Medical Field: CASE STUDIES in the world

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Sirris | Driving industry by technology

130 experts & hight-tech infrastructure

Collective centre of the technology industry • Non profit organization • Industry owned

4,700 industrial interventions (advice, projects, services) •within 1,700 different companies •whose 75% are SME’s •24M EUR turnover

Mission: “Increase the competitiveness of companies of the Agoria sectors through technological innovations”

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Sirris | 24 years of Additive Manufacturing

AM centre – Leading position in EU 16 engineers and technicians 12 high-tech different additive technologies 15 machines in house

Most complete installed base in EU Driving technology companies in applications

Technologies: Nowadays : • Stereolithography (normal & hi-res) • Paste polymerization 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 • Electron Beam Melting (Arcam A2) • Vacuum Casting of Alu, Bronze, Zamak • Laser Cladding (EasyClad) • Laser Beam Melting (MTT) • Bi-material FDM system (MakerBot) • MCOR technology (color 3Dprinter)

Previously : • Laser sintering of metal powder (parts and mould inserts) • 3D Printing of wax (Thermojet) • Fab@home system (for students)

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25/11/2011 5

(…)


25/11/2011 6

• Basic data :

Scan / 3D CAD files – STL

• Pre-treatment :

STL corrections, orientation, supports, 2D slicing

• Manufacturing :

Full automatic

• Post-treatment :

Cleaning, sand blasting, coating, finishing

Σ 2D layers

3D CAD File

3D STL

File

Sliced File


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Rapid Prototyping

• Stereolithography

• Fused Deposition Modeling

• Bi-material 3D Printing

• 3D Printing of wax

• 3D Printing of polymers / plaster

• Selective Laser Sintering

Rapid Prototyping vs Additive Manufacturing

Additive Manufacturing

• Electron Beam Melting

• Laser Beam Melting

• Laser Cladding

• Hybrids of Stereolithography

25/11/2011

Functional

parts

Final

parts

Visual

parts

• Specific materials for

each technology

• Some of them are

biocompatible

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Need of flexibility, complex structures and fast

response for surgery! Very small or even

standard (large) manufacturing series possible

• Evolution of medical imagery technology

=> Easy access to 3D world !

Need for custom implants !

Every human is different (anatomy)

Benefits of Additive Manufacturing @ Medical field

25/11/2011

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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]

The utility of Additive Manufacturing technologies

in the medical field

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Medical Additive Manufacturing Software:



25/11/2011

• 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]

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Main applications:

• Pre-surgical planning:

• Custom implant manufacture

• Physician to physician communication • Powerful patient presentation tool • Medical student/resident education • 3D Surface Scanning/Custom Prosthesis Design

[Z. Corp Medical Modeling Solutions]


[Arcam & Objet technology]

[Objet Connex Eden 500]

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Main applications:

• Pre-surgical planning:

• Implant pre-contouring • Screw trajectory • Screw selection/location • Instrument selection • Technique rehearsal

[Objet]

[Objet]

[Objet Connex Eden 500]

[Objet]

“No matter how good our 3-D graphics are, there is nothing like a model in your hands . . .”



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Main applications:

• Pre-surgical planning advantages:

• Significantly reduces operation time

• Lowers cost • Reduces operation team fatigue

• Enhances patient outcomes • Reduces “re-do” procedures • Minimizes size of incisions • Speeds recovery time • Improves anatomical alignment • Enables multiple procedure rehearsals


[Case study: The Alfred Hospital, Melbourne, Australia]



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Main applications:

• Physician to physician communication • Powerful patient presentation tool • Medical student/resident education


[Sirris ADD] [Sirris ADD] [Sirris ADD] [Sirris ADD]

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Main applications:

• Custom Prosthesis Design • Complex parts manufacturing



[Sirris ADD]

[Sirris ADD]

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Femoral & Total hip implants

• Custom-fit femoral implants

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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/year)

[Sirris ADD]


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Project: “Optobio”

Client: Osseomatrix (Dr Nimal)

• Porous & dense orbital implant in Hydroxyapatite Ca5(PO4)3(OH)


0,5mm

1,4mm

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Project: “Optobio”

Client: Osseomatrix (Dr Nimal)


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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

Project: Surgical Cutting Template • UCL-St Luc (Belgium) • 100% dense Ti6Al4V Titanium

• Build time: 4 hours

• Weight: 25g


• Field: Oral and Maxillofacial Plastic Surgery

[Sirris ADD]

[Sirris ADD]

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Demonstration part: Knee implant • 100% dense Ti6Al4V Titanium with porous Ti6Al4V scaffolds • Build time: 8 hours

• Weight: 170g


• Field: Knee implant orthopaedics

Demonstration part: Craniofacial implant • Sirris (Belgium) • Porous Ti6Al4V Titanium scaffold implant

• Polyamide skull on Z-Corp machine


• Field: Cranio-plastic surgery

[Sirris ADD]

[Sirris ADD]

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Project: “HEROL” (2002: 4 years)

• Goals:

• Enhance the performances of cranio-maxillofacial

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)

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Surgical Guide

• Visyos + Centis 3D-Side • Surgical guide for osteotomy • Build time: a few hours depending on geometries

• Weight: < 200g

• Machine: EOS P390 (SLS Polyamide)

• Field: Bone Surgery (bone tumor)

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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

• Partners (25): www.nanoker-society.org

[Sirris ADD]

[Sirris ADD]

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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)

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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

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[Dr J. Poukens - UHasselt]

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Replacement of Temporomandibular joints

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Thanks for your attention

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Bruno Verlee

mobile: 049186 91 83

Sirris

Liège Science Park, Rue Bois Saint Jean 12,

4102 Seraing

Documents

Agenda - WeLLwell-livinglab.be/wp-content/uploads/2016/03/MSF...04/01/2016 5 04/01/2016 9 Next generation pre-operative manufactured implants: • Custom implant manufacture : •