Arcam A1The future in implant manufacturing

Introducing the future in Implant Manufacturing.The Arcam A1 is the ultimate solution for Additive Manufacturing of medical implants. It is specifically designed for cost-effective production of both standard and custom implants.

Features include:

– Easy powder handling for quick turnaround time.

– Active cooling for shorter build cycles.

– Insulated powder bed for faster builds.

– MultiBeam technology allows for finer surfaces

and faster build speed.

– Application-specific build themes.

Arcam EBM system

The EBM technologyThe Arcam A1 is designed for production of medical implants. The implants are built up layer-by-layer of metal powder melted by a powerful electron beam. Each layer is melted to the exact geometry defined by the 3D CAD model. The Electron Beam Melting technology allows for high energy to be used providing high melting capacity and high productivity. Implants are built in vacuum at elevated tem-peratures resulting in stress relieved implants with material properties better than cast and comparable to wrought material.

The Arcam A1 is capable of delivering a beam power of up to 3500 W while maintaining a scan speed that allows melting of several points simultaneously. The vacuum system is designed to maintain a vacuum level of 1x10-4 or better throughout the entire build cycle.

Standard ImplantsThe EBM technology is a cost-effective process for manufac-turing both press-fit implants and cemented implants. For press fit implants, specifically, the EBM process lends itself for high volume production of implants since both the solid sections and porous sections of the implant are built in the same process step.

Further benefits with EBM production of press-fit implants:

– Single step production of solid and trabecular structures – Structural continuity between solid and porous sections – All-porous implants (augments, wedges, blocks, etc) possible– No high temperature process that could cause grain growth needed to apply the porous structure

Custom ImplantsThe EBM-technology offers a “direct CAD to Metal” process allowing production of patient specific implants using data derived from Computer Tomography (CT). The CT data is used to create an exact CAD model of the desired implant. This CAD model is then used by the EBM machine to build the actual part. Examples of such implants are Craniomaxillofacial (CMF), revision hip implants or different trauma devices.

Acetabular cup with a trabecular structure engineered for random appearance.

Trabecular Structures™ – Engineered Porous MaterialsDesign and manufacture your unique trademark trabelular structures using the EBM technology. When choosing the EBM technology for manufacturing you also break free from design constraints you normally have to consider due to the limited number of technologies available for building porous materials. With EBM in mind for production, new advanced trabecular structures can be developed with a minimum of capital investment and a virtually unlimited freedom in design. To reach the properties you look for in terms of osseointegration, primary fit and appearance you can opti-mize your design in terms of:

– Pore geometry– Pore size– Relative density– Roughness

Example of a trabecular structure built with the EBM process. Material is Ti6Al4V.

Example of a Craniomaxiliofacial (CMF) implant for a severe head injury prepared for surgery. CourTEsy oF Dr. sTEPhEn rousE

Arcam AB | Krokslätts Fabriker 27A, SE 431 37 Mölndal, Sweden | Phone: +46 31 710 32 00 | Fax: +46 31 710 32 01 | info@arcam.com | www.arcam.com

Arcam provides Free Form Fabrication machines for Additive Manufacturing of metal parts. The technology offers ultimate geometric freedom combined with first class material properties. Arcam is guided by our vision to revolutionize the art of manufacturing.Use Arcam to manufacture your future.

ARCAM A1 TECHNICAL DATA

Maximum build size 200x200x180 mm (W x D x h)

Model-to-Part accuracy, long range 1 +/- 0.20 mm (3σ)

Model-to-Part accuracy, short range 1 +/- 0.13 mm (3σ)

surface finish (vertical & horizontal) 2 ra25/ra35

Beam power 50–3000 W (continuously variable)

Beam spot size (FWhM) 0.2 mm – 1.0 mm (continuously variable)

EB scan speed up to 8000 m/s

Build rate 2 55/80 cm3/h (Ti6Al4V)

no. of Beam spots up to ~100

Cooling Active

Vacuum base pressure <1x10-4 mbar

Power supply 3 x 400 V, 32 A, 7kW

size and weight 1850 x 900 x 2200 mm (W x D x h), 1420 kg

Process computer CAD interface PC

CAD interface standard: sTL

network Ethernet 10/100/1000

Certification CE

The EBM process is a cost- effective tool for high

volume manufacturing of orthopedic implants.

Inside the Arcam EBM process – a melt pool in the Ti6Al4V powder bed is created by the powerful electron beam.

1 Long range: 100 mm, short range: 10mm, measured on Arcam standard Test Part (AsTP).2 Measured on Arcam standard Test Part (AsTP). settings optimized for fine surface quality/settings optimized for high build speed.