On customization of orthopedic implants-from design and additive ...
Use of Additive Manufacture in Orthopaedic Implants June 2015
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Transcript of Use of Additive Manufacture in Orthopaedic Implants June 2015
Use of Additive Manufacture in
Orthopaedic ImplantsProfessor Edward DraperExecutive Innovation Manager
JRI Orthopaedics
Open Innovation
External Funding
Total Funding Value
£8.8M Total JRI Value
£1.3M
11 Grant-Funded Projects
JRI Leading on
5 projects
RTD, 5
Academia, 12
Collaborators
SME, 12
Open Innovation
Custom ImplantsComplex Anatomy, Trauma and Revision
‘Standard’ solution not always work
Mass custom Knee – more complex than hip
Results – not
as excellentMany re
asons
Sizi
ng is
impl
icat
ed
Kirby Hitt et al. J Bone Joint Surg Am 2003;85:115-122
©2003 by The Journal of Bone and Joint Surgery, Inc.
Knee Sizing StudyW
idth
Depth
Case for Mass Custom?
Additive – non-customComplex featuresPorous
bone/implant interface
Complex small components
Boring Bit – Validation
Measurement Materials Method
Design Validation Machine
Ultrasonic Cleaning
Predicate Benchmark
Acceptable level
Biocompatibilty
Standards
Measurement Techniques
ElectropolishingPowder Size
Sphericity
Flow Rate
Powder Distribution
J et Milling
HIPing
Liquid CO2
Powder Recovery
Vacuum Nucleation Cycling
Porosity
Porosity Depth
Part position
Part OrientationBioburden
Geometry
Reclaim
Powder Spread
Chemical Composition
Coating - tensile, shear, fatigue,
Surface Finish
Porous form geometry
Surface Finish
Mechanical Strength
Part tolerance
Microstructure
Mechanical Properties
Worst Case
Product Mix
Excess Powder not removed from
implant
Problem Statement
Scan Rate
Layer Thickness
Environmental Factors
Powder Handling
DataTransfer
Measurement Materials Method
Design Validation Machine
ProblemExcess Powder
Changes from ‘Standard’
MetallurgyGeometry
Bio-burden
More than just metal
Polymers
Coatings
In-theatre manufacture In-wound 3D image
Sterile
Manufacture
In-theatre
Bio-printing
Sensors
Different loading
Greater risk
of failure
Sensors give early
warning
Design freedomsComplex arcades of
trabeculae
Could 3D
print th
isDesign?
- Tolerances etc.
Personal Summary
• Additive Manufature– Increasingly important– Orthopaedic implants
• Not Just custom
• Barriers– Validation– Design capability
• An exciting future– JRI leading edge
Thoughts and Notes
• 13.30 USE OF ADDITIVE MANUFACTURE IN ORTHOPAEDIC IMPLANTS
• With unusual anatomy, building an implant to fit the patient• Based on 3D imaging such as MRI and CT• Use of new materials to enhance bone / implant interface• New design freedoms around sensors
Thoughts and Notes
• Commercial - sensitive• Input – ImplantDirect
– With unusual anatomy, building an implant to fit the patient– Based on 3D imaging such as MRI and CT
• Mobelife• SCP• Boring bit - validation• In-theatre manufacture• Use of new materials to enhance bone / implant interface• New design freedoms around sensors• Cell sorting Daniel Saris
– Bioprinting