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Part 01: General considerations and clinical case studies

Biomedical applications of Additive Manufacturing

Masterclass:

Masterclass part 01: • Entirely dedicated to current and mature industrial

applications • Theory – basic principles, technologies, applications and

software • Case studies and general future applications of AM

Masterclass part 02: • Futuristic applications: bio-printing & organ-printing • More theoretical • Current applications, future perspectives and case studies

Organized by SIRRIS the 12th of March 2013 Masterclass: Biomedical applications of Additive Manufacturing 2

11h45: Reception & lunch 12h40: Welcome session – introduction

• Carsten Engel, SIRRIS 13h10: Taking into consideration the technical aspects

• Julien Magnien, SIRRIS 13h50: Taking into consideration the medical aspects

• Bernardo Innocenti, ULB 14H30: From medical images to design of a custom medical

device • Herlien Declerck, Materialise

15h15: Coffee Break (and snow fight)

3 Organized by SIRRIS the 12th of March 2013 Masterclass: Biomedical applications of Additive Manufacturing

15h25: Case study 01 - Practical clinical case study using MIMICS software from Materialise • Bram Lenaerts, Mobelife

16h00: Case study 02 - Clinical support requirement for Additive Manufacturing to be successful: Lessons learned from the Walter Reed Army Medical Center • Stephen Rouse, AM consultant

16h35: Case study 03 - Veterinary case studies – successful AM manufactured bone replacements • Vojislav Petrovic, AIMME

17H10: New features and functions in implants through an innovative design approach and Additive Manufacturing (Laser Beam Melting) • Thomas Töppel, Fraunhofer IWU

17h45: 2nd Coffee Break


17h50: Future perspectives and business opportunities of Additive Manufacturing. Market overview, latest trends in technologies, applications and materials • Thierry Dormal, SIRRIS

18h20: Networking


Welcome session and general introduction

Biomedical applications of Additive Manufacturing

Masterclass:


Aerospace Automotive Construction products

Contracting & Maintenance Electrical engineering Industrial automation Mechatronical engineering

Information and communication technologies (ICT) Metals & materials Metal processing Mounting & cranes

Plastics & composites Security & defence


Leuven Mechatronics

Technology Coaching

Hasselt Materials Engineering

Production Technology

Charleroi Additive Manufacturing Bio- Manufacturing Platform

Brussels Software Engineering & ICT Technology Coaching

Ghent Materials Engineering

Liège Additive Manufacturing

Materials Engineering Nanomaterials


Case study: Femoral & Total hip implants • Today : Mass fabrication of standard femoral implants (& others)


Yes, it will work. But ….


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


Medical Additive Manufacturing Software:

• Materialise: Mimics • Materialise: 3matic • Marcam: Autofab • Able Software Corp: 3D Doctor • Medicim: Maxilim • ProEngineer • New: Lenexa: Analyze • New: Brisbane: Anatomics • (…)

[Mimics & 3-matic - Materialise]


Trends in biocompatible materials used in Rapid Prototyping / Manufacturing:

Metals: • Titanium (Ti6Al4V) • Ti-alloys • Stainless steel • Shape memory alloys (Ni-Ti) – in research • Noble materials (Gold) • …

Ceramics: • Hydroxyapatite (HAP) • Zirconium • Tricalcium phosphate (TCP) • Alumina • …

Polymers: • PTFE (Polytetrafluoroethylene) • PMMA (Polymethyl methaacrylate) • PE (Polyethylene) • PEEK • PEKK • … others, too but not implantable

Others: • Hydrogels + Human cells


Leading 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]

[Sirris ADD]


[Objet]

[Objet] [Objet Connex Eden 500]

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

Leading applications: • Pre-surgical planning:

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

[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 • Minimizes size of incisions • Speeds recovery time • Improves anatomical alignment • Enables multiple procedure rehearsals


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


Leading applications: • Physician to physician communication • Powerful patient presentation tool • Medical student/resident education • Custom Prosthesis Design • Complex parts manufacturing

[Sirris ADD]

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

[Sirris ADD]

[Sirris ADD]


0,5mm

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

[Sirris ADD] [Sirris ADD]


[Dr J. Poukens - UHasselt]

[Walter Reed Army Medical Center, Washington DC, USA ]



[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]


Ti6Al4V: E(GPa) = 110 !


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

+ + [Sirris - ADD]

[Sirris - ADD]


[Université de Mons, Faculté Polytechnique]

Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)



« Medical Additive Manufacturing & Rapid Prototyping »

« Sirris »


Carsten ENGEL Biomedical Engineer Additive Manufacturing Department Mail: [email protected] Mobile: +32 498 91 94 50 Skype: Carsten-Engel SIRRIS Rue Auguste Piccard, 20 B-6041 GOSSELIES BELGIUM http://www.sirris.be