dépôts de couches minces pour applications médicales

confidential

Bodycote 5eme Seminar

Dépôts de couches minces pour applications

médicales

confidential2

Medical Coatings Key Site Map

Olten CH

ISO13485Le Mee FR

ISO 13485

Consett UK

ISO 13485

USA-NJ

Rockaway

ISO 13485

Wuxi, China

ISO 9001

(ISO 13485)Chassieu

France

ISO 13485

Cleveland OH

2015, ISO 13485

Guanzhou, China

ISO 9001

(ISO 13485)

Taegu, Korea

ISO 9001

(ISO 13485)Portland OR

2015 ISO 13485

confidential3

Ionbond – Coating Equipment Technologies (vacuum technology)

PVD

Physical Vapor Deposition

CVD

Chemical Vapor Deposition

PACVD

Plasma Activated Chemical Vapor Deposition

Ionbond – Equipment Coating Portfolio

Deposition from 100°C to

500°C

Coating thickness

depends on exposure to

coating source

Deposition >800°C

Uniform coating thickness

Stimulation of diffusion

between different

materials

Deposition 150-200°C

Coating thickness

depends on the space to

generate plasma

confidential

Coating Equipment Technologies

Physical Vapor Deposition (PVD)

Arc evaporation

Magnetron sputtering and HIPIMS

4

Chemical Vapor Deposition

(CVD)

Plasma Activated CVD

confidential

Coatings for Medical Application

5

Medthin™ biocompatible coatings for implants, tools and instruments

Certified coatings for medical applications

Medthin™ biocompatible coatings

Wear and friction reduction

Ion barrier coatings for implants

Color coding and glare reduction for

instruments

Improved edge retention for cleaner cut

Cell attachement

ISO 13485

confidential

Product and Services Overview

6

Other Services

A comprehensive portfolio of coating services and coating equipment

Equipment

CVD

Coating Services

Cutting

Tools

Forming

Molding

Automotive Deco

Sports

Luxury

MedicalIndustrial

Racing

Aerospace

Tooling Components

CVA

confidential

Ionbond Coatings for the Tool Market

Ionbond™ PVD and Bernex™ CVD coatings improve productivity

7

Complete portfolio

Hardcut™, Crosscut™, Maximizer™

Ionbond™ 01 TiN, 30 CrN etc.

Bernex™ 10 TiN-TiC-Tin, 29 Al2O3 etc.

Less lubricants and coolants

For longer lasting tools

Ionbond™ 90 Concept, 43 a-C:H

Bernex™ 29 Al2O3 , 32 CrC etc.

Improved product finish

confidential

Coatings for Component Applications

Increased component lifetime, reduced friction, higher output for less input

8

Higher power density for modern engines

Tribobond™ DLC coatings

Engine and fuel injection components

TS 16949

Maximum power output

Tribobond™ DLC and high temperature

resistant coatings

Powertrain, Drivetrain

Custom engineered

confidential

Coatings for Component Applications II

Lower maintenance requirement, higher uptime and less lubrication

9

Higher load and reduced wear

Tribobond™ 46 CrN+a-C:H:W

Bernex™ 32 CrC

Reduced service cost

Tribobond™ 01 TiN, 30 CrN, 40 a-C:H:W

Bernex™ 66 Al

Improved lifetime

Aerospace industry certifications

confidential

Coatings for Decorative Surfaces

Hard and durable decorative coatings preserve the good look for years

10

Scratch and corrision resistant

Decobond™

Interior and exterior goods

Automotive

A new standard in luxury goods

Diamondblack™ ADLC

Watch cases and movement components

Fashion accessories

confidential

Bernex™ CVD and CVA Equipment

Equipment for carbide inserts, forming tools and component coatings

11

CVD

Bernex™ BPXpro

Industry standard system

Large coating portfolio

Inserts and forming tools

CVA

Bernex™ ALUVAP

Al diffusion coatings for turbine blades

3D process reaches cooling channels

confidential

Medthin - Thin Film Coatings for Medical

Thin films are: nitrides... Ceramic type of structures

Thickness ranging between 1 to 20 µm.

Biocompatible and possible to use on implants

12

confidential

Biocompatibility Evaluation-Master Files

13

confidential

Reason: 10 to 15 % of patients suffer from an epicutaneous metal allergy

14

Source: Schäfer T et al.,

Epidemiology of contact allergy in

adults, Allergy, 2001.

13,1

2,4

1,1

5,8

1,40,7

20,4

3,4

1,5

0

5

10

15

20

25

Nickel Cobalt Chrome

Popula

tion in %

MenWomen

All Together

60% of revision

are caused by

metal allergy

Why MedthinTM on Implants?

confidential

Symptoms of metal allergies

15

1

5

Eczema after metal implantation Effusion after metal implantation

Source: Thomsen M, Rozak M, Thomas P. Pain in a chromium-allergic patient with total knee arthoplasty: disappearance of

symptoms after revision with a special surface-coated TKA – a case report. Acta Orthopaedica 2011; 82 (3):x-x. Epup ahaed of print

Symptoms of allergic reactions:

pain

eczema

aseptic implant loosening

impaired wound healing

Why MedthinTM on Orthopedic Implants?

confidential

Expectations from Coatings Performance

16

Wear reduction

Ion release reduction from substrate

Leading to longer life time of implants, younger patients to profit

Coatings have a cost which still represent a clear benefit

Avoid potential catastrophic failures of bulk ceramics

confidential

Generation I: PVD Arc Evaporation Coatings for

Implants

State of the art: cathodic arc eveporation, «Random Arc»

17

17

- 25 V - 100 V

SS

N

Substrate

Evaporation

source OFF

Evaporation

source “ON”,

shape I

Coating

Evaporation

source “ON”,

shape II

confidential

TiN as deposited

Ra~0.4µm

5-10 microns coating

thickness

18

TiN after polishing

Ra~0.02µm

Generation I: PVD Arc Coatings for Implants

SEM mapping

of

macroparticles

confidential

-Dental

-Hip

-Knee

-Spine

-Ankles

-Shoulders

-Specials

-Screws

-Eye


confidential

Pappas et al; 61st Annual Meeting ORS, Mar ‘94.

Hip Simulator UHMWPE Wear Testing

TiN Coated Femoral Head

9 um TiN coated Ti-6-4

resurfacing cups.

Surface finish = 0.04 um.

Articulating against UHMWPE.

Distilled H2O @ 37oC.

4 station hip simulator.

Load: 0-2200N.


confidential

.1

.2

.3

.4

.5

.6

0

CYCLES X1065 10 15 20 25 30 35 40 45 50

0.045

Co-Cr 32mm

TiN 32mm

TiN 47mm

Pappas MJ, Makris G, Buechel FF: Titanium Nitride Ceramic Film Against

Polyethylene A 48 Million Cycle Wear Test.

Clinical Orthopaedics and Related Research 317:64-70, 1995.

HIP SIMULATOR COMPARATIVE WEAR OF

Co-Cr-Mo vs. TiN


confidential


TiN coating substantially reduces the Co ion release from the substrate

TiN substantially reduces wear of UHMWPE

Implants coated with TiN are in the market since Y1997

Statistically it appears that Generation I coated implants can last longer

than 15years

22

Ion release test:

Inductively coupled plasma mass

spectroscopy (ICP-MS) analysis of

the collected

OrthoPOD test liquids

CoCrMo 0.9 <0.6 0.1

TiN

coated <0.1 <0.6 <0.1

Co Cr Momg/L

Ion Release from CoCrMo

confidential

Ion Release Benchmarking: Generation I

23

J Fischer, X G Hu, J. L. Tipper, T.D. Stewart, S. Williams, M.H. Stone, C. Davies, P. Hatto,

J. Bolton, M. Riley, C. Hardaker, G.H. Isaac, G. Berry and E. Ingham,

Proc Instn Mech Engrs Vol 216 part H J. Enginnering in Medicine

Medthin Coatings against CoCrMo counter part (CoM- Coating against Metal): Over

40% drop of metal ion release from CoCrMo due to barrier formed by Medthin

coatings (against ion release).

Monolayer: MedthinTM 01 TiN, typical

film thickness from 6-10 µm

Monolayers:: MedthinTM30 CrN,

typical film thickness from 3-10 µm

Ion C

oncentr

ation µ

g/l

confidential

Generation II: Steered Arc and Magnetron

Sputtering

Goal: Less coating roughness less coating thickness

Cathodes ON/OFF make multilayers, evap/cooling reduces droplet emission

Steered arc leads to less droplets, less energy density on the target

Hybrid steered arc and magnetron processes

Planar rectangular targets

confidential

Generation II Steered Arc and Magnetron

Sputtering

Coating Structure - denser films

Thinner films, 3-6 µm

Les rough filmes Ra~0.150µm

Less time used for polishing

Multilayers in the market since Y2007

25

confidential

Generation II: Steered Arc and Magnetron

Sputtering

Ion release reduction from metal implants (Co, Cr, Mo, Ni etc) up to 98%

Wear reduction from UHMWPE up to 65%

26

98

%

98

%

95

%

90

%Ion C

oncentr

atio

n µ

g/l

0

50

100

150

200

250

300

350

400

450

Mo Ni Co Cr

CoCrMo

Both components coated

AS reference

confidential

Generation III: Pulsed Plasma Technologies

27

HiPIMS 1

DC 7

DC 3 HiPIMS 5

Heater

Bias

Pulse

single

Pulse

single

E2E1E1 E2

DC

Powersupply

DC

Powersupply

Pulsed

Plasma

Magnetron

Sputtering

source,

planar

rectangular

Increase energy and produce coating quasi

without droplets, lower roughness

Use of pulse technologies for high energy

pulse plasma , good coating adhesion

confidential

No Evaporation, instead , Ar ions sputter target

materials to form a plasma

Sputter yield depends on the material, e.g. Ti is high

& Nb is lower

28

- 500 V

- 100 V

SS

N

Argon (Inert) gas

ions

Coating

substrate

Sputtering

source ON

Generation III Pulsed Plasma Technologies

confidential29

PPT – Pulse plasma technologies

Application of short, high energy pulses promotes:

• High ionization of coating flux leading to:

Dense coating structures

Good compound formation

Enhanced coating adhesion

• Allows deposition of non-conductive

materials

Generation III Pulsed Plasma Technologies

confidential

Generation III pulsed plasma technologies

30

Keep film thickness 3-7max microns

Eliminate the droplets, avoid

polishing

Ra<0.05µm as deposited

Deposited on multiple geometries

Quite good coating uniformity

confidential

Generation III, MeSiN coating shows a wear track, sort of “run in”

Similar wear of UHMWPE pins compared with generation II

31


confidential


SiNx coatings on CoCrMo reduced the release of metal ions into the solution by two orders of

magnitude.

CoCrMo showed a dissolution rate between 0.7 and 1.2 nm/day,

SiNx coatings showed dissolution rates between 0.2 and1.2 nm/day. Si is not a problem for patients

7um SiN coating lasts for 48 years

32

confidential

Polishing Techniques

Slow manual polishing

Much quicker, Drag polishing

sufficient for magnetron PVD,

PACVD and pulsed coatings

33

confidential

Examples of Application on Implants

34

Generation I

MedthinTM 01

TiN on ASTM

F136 Ti-6Al-

4V . Coating

deposited with

high thickness

Generation II

Medthin

multilayer

PVD on

CoCrMo

Generation III

pulse

technologies

coated knee

component

Medthin 43 ADLC

and its possible

multilayers

PEEK BaSO4 with

top MedthinTM 65

confidential

ADLC coated implants - Application

MedthinTM 43 ADLC used for spinal implants

Sold in 25 different countries

8 years in the market

Implanted over 10’000 discs worldwide

35

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

0.00 1.00 2.00 3.00

depth [µm]

co

nce

ntr

atio

n [

at%

]

H

C

O

Si

Ar

Cr

Fe

W

RBS analysis of the ADLC

coating

confidential

Scanning Electron Micrographs

Showing the coating roughness and morphology

Some heterogeneity (porosity) was noticed at high magnification

36

MedthinTM 65 Ti on PEEK – Morphology

10µm

MedthinTM 65 with 5 µm thickness

confidential

Antireflective Coatings

37

Performance improvements with Medthin™ 20 AlTiN,

Goal: Minimize eye fatigue, provide high contrast

between instruments and tissue

Laser Marking Gold over AlTiN

Medthin™ 20 AlTiN used in high volume

applications, instruments and dental

confidential

65

100

138

180

0

50

100

150

200

a-C:H (ADLC) Cr + a-C:H Cr + a-C:H:W

+ a-C:H

Cr + CrN +

a-C:H

Lo

ad

carr

yin

g c

ap

ab

ilit

y [

%]

.

CrxN/ADLC multilayer for

instruments

Anti Reflection and Low Friction

All New DLC coatings with CrN interfaces

MedthinTM 41 MedthinTM 42MedthinTM 40MedthinTM 43

confidentialFootnote39

MedthinTM 42 CrN/ADLC

DLC coating amourphous

and dense

CrN coating polycrystalline

Dense Structures; High Adhesion

CrN coating if not top

coated with DLC grain

boundaries are a pathway

to the substrate material

and chemical changes

may arise including

corrosion phenomena

confidential

Some Examples MedthinTM for Instruments

40

Medthin™ 01

TiN or

Medthin™ 60

ZrN

Medthin™ 20

AlTiN

Medthin™33

CrCN

Medthin™ 40,

41, 42

multilayers DLC

Medthin™ 43

ADLC

Thickness mesured in

the coupons [µm]

2-6 2-6 1-4 2-6 2-3

Adhesion [N] or class

(ISO 26443)

Excellent Excellent Excellent Very Good Average

Color Appearance Gold (TiN), light

gold (ZrN)

Gray-Black Gray-Black Gray-Black Black

Surface preparation

prior to coating

Passivation ok,

Ra<0.5µm ok

Tolerates better surface oxides/ blasting/non conductive surfaces prior to

coating

Passivation ok,

Ra<0.2µm ok

Adhesion suffers

from surface

contaminations

Cleaning and

sterilization after

coating

Resistant/Rob

ust

Should not be

clean with Al

solvent agents

Resistant/Robust to cleaning and all sterilization types and

number of cycles

Corrosion

improvement

compared with non

coated SS

Good Good Very Good, rather

dense coating

Excellent, Good,

confidential

Laser Marking Parameters

41

MedthinTM01 TiN

MedthinTM33 CrCN

MedthinTM20 AlTiN

MedthinTM DLC

Laser marking made at different depths

confidential

Medthin™ Coating Application Areas

42

Dental Instruments – color coding

Dental Implants and Abutments –

reduced wear

Heart Implant – ventricular assist

cardiac pump systems

Spine Implants – cell atachment onto

PEEK material

Spine Implants – cervical disk

applications for wear and metal ion

release reduction

Hip Instrument – intramedullary reamer

improved performance

Hip Implant – hip resurfacing implant head

reduced wear of UHMWPE

Knee Implant – reduced wear and metal

ion release

Knee Implant –improved bone cell

attachment

Ankle Implant – reduced wear and

abrasion

Small Bone Implants – reduced

wear and extended life

confidential

Contacts

43

Dr. Antonio Santana

Head Segment Medical

+41786555916

Or

[email protected]

mailto:[email protected]

dépôts de couches minces pour applications médicales

Documents