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Sirris Medical Ceramic Applications
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Transcript of Sirris Medical Ceramic Applications
le centre collectif de l’industrie technologique belge
The collective centre of the Belgian technology industry
Our centre
Federation for the technology industry
Collective centreof the technology industry
• Nonprofit organisation
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• Nonprofit organisation• Industry owned
“Increase the competitiveness of companies of the Agoria sectors through technological innovations”
Mission
© sirris 2011 Charleroi | www.sirris.be | [email protected] |
Our technological sectors
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
Local presence, near the companies
LeuvenMechatronics
Technology Coaching
HasseltBrussels
GhentMaterials Engineering
HasseltMaterials EngineeringProduction Technology
CharleroiAdditive ManufacturingBio-Manufacturing Platform
BrusselsSoftware Engineering & ICTTechnology Coaching
LiègeAdditive ManufacturingMaterials Engineering
Nanomaterials
Additive Manufacturing Process
• Basic data :
Scan / 3D CAD files – STL
• Pre-treatment :
STL corrections, orientation, supports, 2D slicing
3D CAD File
3D STL File
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STL corrections, orientation, supports, 2D slicing
• Manufacturing :
Full automatic
• Post-treatment :
Cleaning, sand blasting, coating, finishing
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Σ 2D layers
Sliced File
Rapid Prototyping
• Stereolithography
• Bi-material 3D Printing
• 3D Printing of wax
• Selective Laser Sintering
• 3D Printing of polymers / plaster
Rapid Prototyping vs Additive Manufacturing
Additive Manufacturing
• Electron Beam Melting
• Selective Laser Melting
• Laser Cladding
• Hybrids of Stereolithography
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• 3D Printing of polymers / plaster
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
Functionalparts
Final parts
Visual parts
SIRRIS – World leader: Most complete machine park
• 15 engineers and technicians • Two locations: Liège (10 p.) and Charleroi (5 p.)
Rapid Prototyping / Tooling / Manufacturing
• Stereolithography (normal & hi-res)• Paste polymerisation for ceramics and metals (Optoform)
Sirris ADD capacities & competencies
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• Paste polymerisation for ceramics and metals (Optoform)• 3D Printing of plaster and metal powder• Laser sintering of polymeric powder (PA,…): P360 – P390• Objet Connex 500: bi-material• Laser sintering of metal powder (parts and mould inserts)• Electron Beam Melting (Arcam A2)• 3D Printing of wax (Thermojet)• Vacuum Casting of Alu, Bronze, Zamak• Laser Cladding (EasyClad) • Selective Laser melting (MTT)
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
• Evolution of medical imagery technology
=> Easy access to 3D world !
Need for custom implants !
Benefits of Additive Manufacturing @ Medical field
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Need of flexibility, complex structures and fast
response for surgery! Very small or even
standard (large) manufacturing series possible
Every human is different (anatomy)
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
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
The utility of Additive Manufacturing technologies
in the medical field
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• Surgery• Follow up
© sirris 2011 Charleroi | www.sirris.be | [email protected] |
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[Sirris ADD]
[Sirris ADD][Sirris ADD]
Medical Additive Manufacturing Software:
ADD capacities & competencies
• Materialise: Mimics• Materialise: 3-matic• Marcam: Autofab• Able Software Corp: 3D Doctor• Medicim: Maxilim
ProEngineer
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25/11/2011© sirris 2011 Charleroi | www.sirris.be | [email protected] |
• ProEngineer• New: Lenexa: Analyze• New: Brisbane: Anatomics• (…)
[Mimics & 3-matic - Materialise]
Indirect Manufacturing: Optoform process
le centre collectif de l’industrie technologique belge
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Optoform
Generalities:
• Commercially not available any more• Flexible technology (hybrid SLA):
•Development of very different materials• Possible materials:
•Soft, hard, metallic and ceramic• ISO 13485 certified @ Sirris
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Fabrication steps:
• Preparation and fabrication of the bulk material• CAO / CAD File processing• Automated process manufacturing• Cleaning and recycling of the non-used material• Debinding & Sintering process
[Sirris ADD]
Optoform
Features:
• Layer thickness: 20 - 200µm• Argon laser 400-800mWatt at 351nm and 365nm• Max. Size: 250-350-500mm• Several building plates with variable sizes well suited to small parts and expensive materials• Supports needed
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Material Requirements:
• Composition :Resin+ Fillers (20% to 70% Vol.) + Photo-initiator + Wetting agent + rheological/ thixotropic Agent
• Consistency : Firmness of a toothpaste (Bingham’s model)• Good Lifetime : the filler should not deposit sediment• No UV absorption by the filler ↔ Layer thickness• Support removal & cleaning: not always easy (isopropanol, water,…)
Materials:
• Alumina• Alumina with 8% of nano Zirconia• Hydroxyapatite• α & β Tri-calciumphosphate• Zirconia• SiC• Stainless steel• Titanium
Optoform
[Sirris ADD]
[Sirris ADD]
• Titanium
• Ceramics & metals need a post-process of debinding & sintering
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[Sirris ADD]
[Sirris ADD][Sirris ADD]
Optoform & medical field: CASE STUDIES
Ongoing statuts:
• Porous scaffolds in Hydroxyapatite Ca5(PO4)3(OH)• Diameter ~= 10mm• Macro-porosity ~= 0,5mm• Tests various scaffold structures for bone integration• In vivo testing (rabbits & rats)• Field: Spinal implants & Maxillofacial Surgery
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• Field: Spinal implants & Maxillofacial Surgery• Spinal implants (HAP/TCP): 10.000 manufactured so far (November 2011)
[Sirris ADD][Sirris ADD][Sirris ADD][Sirris ADD]
06/12/2011© Sirris | www.sirris.be | [email protected] |
Optoform & medical field: CASE STUDIES
[Sirris ADD]
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0,5mm
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[Sirris ADD] [Sirris ADD]
[Sirris ADD]
[Sirris ADD]
[Sirris ADD]
Optoform & medical field: CASE STUDIES
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06/12/2011© Sirris | www.sirris.be | [email protected] |
[Sirris ADD] [Sirris ADD]
Sirris Additive Manufacturing: Contact
Carsten ENGEL
R&D Biomedical Engineer
Mail: [email protected]
19© sirris 2011 Charleroi | www.sirris.be | [email protected] |
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06/12/2011
Mail: [email protected]: +32 498 91 94 50Skype: Carsten-Engel
SIRRISRue Auguste Piccard, 20B-6041 GOSSELIES BELGIUMhttp://www.sirris.be