Dental and Surgical Applications of Selective Laser Melting
Transcript of Dental and Surgical Applications of Selective Laser Melting
Medical Applications of SLM
© PDR November 2007
Dental and Surgical Applications of Selective Laser Melting
Dr. Richard Bibb
Medical Applications of SLM
© PDR November 2007
Rapid Manufacturing
The following examples adhere to this conference’s
definition of RM
They are end use parts, made directly from CAD data using
a layer additive manufacturing method
These cases exploit RM to produce custom-fitting end-use
medical devices for both short-term and long-term
applications
Medical Applications of SLM
© PDR November 2007
Medical Applications of SLM
© PDR November 2007
SLM research at PDR
Design rules – feature capabilities and design guidance
Support generation – strategies and part orientation
Materials – composition, particle size, distribution, etc.
Performance – including tensile and fatigue testing
Surface finishing – rapid, labour free finishing techniques
Reliability and repeatability
Powder quality, handling and storage
Medical Applications of SLM
© PDR November 2007
Removable Partial Denture Frameworks
Why? – To investigate moving to an entirely digital design
and build procedure in dental technology
How? – Using 3D Scanning, advanced CAD and SLM
Obstacles – Case studies time consuming, finding our own
way!
Successes – Several cases done, test fitted to patients and
results published
Medical Applications of SLM
© PDR November 2007In collaboration with UWIC Centre for Dental Technology
RPD Case 1
Designed on 3D patient data
using SensAble
FreeForm
software
Designed
according to
established
dental technology protocols
Medical Applications of SLM
© PDR November 2007In collaboration with UWIC Centre for Dental Technology
RPD Case 1
Made using SLM in F75 Co-Cr
Fitted the patient
cast very well
Polishing
revealed
excellent density
Good clasping
force
Medical Applications of SLM
© PDR November 2007
RPD Case 2
RPDs are oriented such that the
supports are
minimised and
whilst not
contacting the fitting surface
In collaboration with UWIC Centre for Dental Technology
Medical Applications of SLM
© PDR November 2007
RPD Case 2
This case was successfully build
in both 316L
Stainless Steel
and F75 Co-Cr
Co-Cr provides
better clasp force
and withstands
repeated use better than 316L
In collaboration with UWIC Centre for Dental Technology
Medical Applications of SLM
© PDR November 2007In collaboration with UWIC Centre for Dental Technology
RPD Case 2
Close up showing the accurate fitting
of the clasps
Successfully test
fitted to the patient in clinic – next
slide
Medical Applications of SLM
© PDR November 2007In collaboration with UWIC Centre for Dental Technology
Medical Applications of SLM
© PDR November 2007
The following cases were conducted by the Centre for
Applied Reconstructive Technologies in Surgery
CARTIS is a collaborative joint venture between the
Maxillofacial Unit of Morriston Hospital and PDR
www.cartis.org
Medical Applications of SLM
© PDR November 2007
Custom fitting surgical guides
Why? – To transfer computer-aided surgical planning to
the operating room accurately
How? – Using CT data, advanced CAD and SLM
Obstacles – designing the templates to account for the
restrictive environment of a surgical incision
Successes – 10 cases conducted for osteotomy and
drilling in UK and USA, results presented and published
© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 1
This case was
planned on CT
data using 3D CAD
It required to stages
Stage 1 – Le Fort 1
Osteotomy
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 1
This case was
planned on CT
data using 3D CAD
It required to stages
Stage 2 – another
osteotomy to reduce the maxilla
by 4 mm
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 1
This case was
planned on CT
data using 3D CAD
It required to stages
Stage 2 – another
osteotomy to reduce the maxilla
by 4 mm
Medical Applications of SLM
© PDR November 2007
Surgical Guide
Case 2
Another Le Fort 1
osteotomy case
was planned on
CT data using 3D
CAD
A different guide
design was
attempted
© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007
Surgical Guide
Case 3
The following
cases are for
osseointegrated
implant placement
The implants are
used to fix
prosthetic ears like
this one
© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 3
The prosthetic ear
clips onto the bar
which is held to the
skull with the
implants
Exact placement of
the implants is
critical
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 3
The implant
positions are
planned by the
surgeon and
prosthetist
The guide is
designed to
include orientation and patient name
(removed) from the
images
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 3
The guide was
made using SLM in
316L stainless
steel
The guide was
used in surgery
and the result was
successful
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 3
The holes are
drilled precisely
and the implants
fitted
Once the bone has
healed abutments
are screwed to
these implants and protrude through
the skin
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Surgical Guide
Case 4
The implant
positions are
planned as before
and the guide
designed
Medical Applications of SLM
© PDR November 2007© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007
Prosthetic retention
Why? – as part of research into the computer-aided design
and manufacture of maxillofacial prostheses
How? – SLM has been used to attempt to create the
retention elements of the prostheses
Obstacles – working at a very small scale, very accuracy
required
Successes – some cases attempted and results published but work is on going
© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007
Prosthetic Retention
Soft tissue, facial prosthesis design using scan data and FreeForm CAD
Bar made in 316L Stainless Steel by SLM, other RP processes used for other components
© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007
1st attempt at and SLM bar
SLA substructure
ThermoJet wax pattern
© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007
Prosthetic
Retention
Improved bar
made by Liverpool
University on the
SLM 100
Precise fit and
good polished
surface finish
make this clinically acceptable
© CARTIS – www.cartis.org
Medical Applications of SLM
© PDR November 2007
Discussion
SLM has proved a successful or clinically feasible RM
method for these end-use medical devices
More work is required to fully realise its potential
RM requires scan data, advanced CAD, new design and
clinical protocols in an integrated approach
More work is needed to produce a more highly efficient work
flow
Medical Applications of SLM
© PDR November 2007
Conclusions
PDR research has shown that SLM is a feasible RM process
for a range of medical, dental and surgical devices
We have recently improved our build processes to produce
virtually 100% dense parts
Further research will improve the process with specific
attention on reliability, repeatability, speed and surface
finishing