Review of medical 3D printing technology and its possible endovascular applications

Peter Mercelis, Phd

Dir. Applied Technologies Healthcare – 3DSystems

3D printing technology basics

• Basic principle: 3D object is manufactured as a stack of 2D layers that are interconnected

• Various technologies depending on type of material and mechanism of consolidation; polymers, metals, ceramics, composites, etc.

3D printing technology basics

• Inherent advantages of 3D printing: – Shape freedom:

• Ideal for anatomical shapes and patient-specific geometries

• Facilitates production of porous cell-growth scaffolds

– Direct digital manufacturing: • Ideal to accept medical imaging input

• Short lead times

• Distributed design and manufacturing setups

• Multiple materials including biocompatible metals and polymers and sterilizable plastics

Patient specific medical devices

• Patient specific medical devices – Hearing aids – Dental prostheses

• Main drivers for adoption of 3DP: – Replacement of labor-intensive design and

manufacturing – Improved precision – Improved functionality

Patient specific medical devices

The World’s First Total Mandible Replacement

Acetabular

Implant

Surgical templates for mandible reconstruction

Volume manufacturing of medical implants

• Volume manufacturing of standard medical devices – Orthodontic implants – Orthopedic implants – Spinal implants – Components of implanted medical devices

• Main drivers for adoption of 3DP: – Integration of osseoconductive bone scaffolds – Allows fully anatomical designs; no manufacturing

limitations – Lower manufacturing costs – Short lead times

Spinal fusion implant Acetabular cup

Anatomical models

• Complimentary to simulation didactic materials – 1:1 scale 3D printed model – Real 3D view of specific anatomy or

real procedure scene – Remarkably detailed anatomical

models – Valuable haptic tool for surgical

training

• Quick customization of models to fit different training needs

• Great improvement of model accuracy over the years

Anatomical models

• CJP – Gypsum based, full color – Removed from powder bed, cleaned, infiltrated for

strength – Not sterilizable

• SLA – Acrylic-like, semi-translucent, photo-reactive dye for

selective color of structures in magenta – Support structures removed, washed, UV-cured – Sterilizable (steam)

• MJP – Multiple materials and material properties in one print – In development

Anatomical models

• DICOM segmentation and 3D conversion is first step

• 3D model adjustment

• Expert review

• Adjust models for printability

3D printed models

• Flexible materials possible with variable rigidity

Fontan

MR: Slices =1.2mm, pixels = 0.586mm

Senning

MR: Slices = 1.4mm, pixels = 1.40mm

Vascular Ring

MR, Slices = 4mm, pixels = 1.027 Combined low resolution volumetric data with measurements to create model design

DORV

CT: Slices = 0.7mm, pixels = 0.346mm

Procedural planning: aiming for highest precision

Case illustration by Dr. Katzen, Baptist Health South Florida

Future outlook

• Near to mid term applications: – Use of anatomical models for preoperative planning and

communication – Biodegradable polymer devices – Cell and tissue printing models for pre-clinical drug screening – Cell therapy based on 3D printed cell growth structures;

• Inert or bio-degradable 3D printed scaffolds as cell culturing surface • Target domains: cartilage repair, neurology, cancer treatment,

orthopedic, ophthalmology, cardiovascular, etc.

• Long term applications: – Patient specific stents – Biodegradable metal 3D printed implants – 3D printing of fully functional organs or organ tissue

• Challenges; cell biology/behavior rather than 3D printing challenge

Thank you for your attention

• Contact information:

Peter Mercelis

Peter.Mercelis@3dsystems.com

www.3dsystems.com