Use of Additive Manufacture in

Orthopaedic ImplantsProfessor Edward DraperExecutive Innovation Manager

JRI Orthopaedics

Open Innovation

External Funding

Total Funding Value

£8.8M Total JRI Value

£1.3M

11 Grant-Funded Projects

JRI Leading on

5 projects

RTD, 5

Academia, 12

Collaborators

SME, 12

Open Innovation

Custom ImplantsComplex Anatomy, Trauma and Revision

‘Standard’ solution not always work

Mass custom Knee – more complex than hip

Results – not

as excellentMany re

asons

Sizi

ng is

impl

icat

ed

Kirby Hitt et al. J Bone Joint Surg Am 2003;85:115-122

©2003 by The Journal of Bone and Joint Surgery, Inc.

Knee Sizing StudyW

idth

Depth

Case for Mass Custom?

Additive – non-customComplex featuresPorous

bone/implant interface

Complex small components

Boring Bit – Validation

Measurement Materials Method

Design Validation Machine

Ultrasonic Cleaning

Predicate Benchmark

Acceptable level

Biocompatibilty

Standards

Measurement Techniques

ElectropolishingPowder Size

Sphericity

Flow Rate

Powder Distribution

J et Milling

HIPing

Liquid CO2

Powder Recovery

Vacuum Nucleation Cycling

Porosity

Porosity Depth

Part position

Part OrientationBioburden

Geometry

Reclaim

Powder Spread

Chemical Composition

Coating - tensile, shear, fatigue,

Surface Finish

Porous form geometry

Surface Finish

Mechanical Strength

Part tolerance

Microstructure

Mechanical Properties

Worst Case

Product Mix

Excess Powder not removed from

implant

Problem Statement

Scan Rate

Layer Thickness

Environmental Factors

Powder Handling

DataTransfer

Measurement Materials Method

Design Validation Machine

ProblemExcess Powder

Changes from ‘Standard’

MetallurgyGeometry

Bio-burden

More than just metal

Polymers

Coatings

In-theatre manufacture In-wound 3D image

Sterile

Manufacture

In-theatre

Bio-printing

Sensors

Different loading

Greater risk

of failure

Sensors give early

warning

Design freedomsComplex arcades of

trabeculae

Could 3D

print th

isDesign?

- Tolerances etc.

Personal Summary

• Additive Manufature– Increasingly important– Orthopaedic implants

• Not Just custom

• Barriers– Validation– Design capability

• An exciting future– JRI leading edge

Thank you

Any questions?

edward.draper@jri-ltd.co.uk

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Thoughts and Notes

• 13.30 USE OF ADDITIVE MANUFACTURE IN ORTHOPAEDIC IMPLANTS

• With unusual anatomy, building an implant to fit the patient• Based on 3D imaging such as MRI and CT• Use of new materials to enhance bone / implant interface• New design freedoms around sensors

Thoughts and Notes

• Commercial - sensitive• Input – ImplantDirect

– With unusual anatomy, building an implant to fit the patient– Based on 3D imaging such as MRI and CT

• Mobelife• SCP• Boring bit - validation• In-theatre manufacture• Use of new materials to enhance bone / implant interface• New design freedoms around sensors• Cell sorting Daniel Saris

– Bioprinting