tips for better 3d printing for medical applications

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Tips for 3D printing for medical applications

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Thank you to our sponsor

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q  This webinar will be available afterwards at www.designworldonline.com & email

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Before We Start

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Leslie Langnau Design World

Moderator

John Murray President & CEO

Concept Laser, Inc.

Katie Weimer Vice President

of Medical Devices 3D Systems


Gil Robinson Senior Applications

Engineer Stratasys, Verticle

Solutions

Meet your presenters…

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Ka#e Weimer, MS Vice President, Medical Devices

August 26, 2015

TIPS FOR BETTER 3D PRINTING OF MEDICAL APPLICATIONS

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Chuck Hull Inventor of 3D Printing First 3D Printed Part March 9, 1983

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February 5, 2015

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Material Extrusion: “An AM process in which material is selecMvely dispensed through a nozzle or orifice” Material Je7ng: “An AM process in which droplets of build material are selecMvely deposited” Stereolithography: (vat photopolymerizaMon) “An AM process in which liquid photopolymer is selecMvely cured by a light acMvated polymerizaMon Powder Fusion: “An AM process in which thermal energy selecMvely fuses regions of a powder bed”

Standard Terminology for AddiMve Manufacturing Technologies (ASTM F2792)

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Direct Metal PrinMng (DMP)

SelecMve Laser Sintering (SLS)

Stereolithography (SLA)

Fused DeposiMon Modeling (FDM)

ColorJet PrinMng (CJP)

MulMJet PrinMng (MJP)

#DWwebinar Di Prima, Ma,hew. Presentation: “FDA Technical Perspective on Additive Manufacturing” Additive Manufacturing for Medical. Boston July 2015

•  70+ AM devices cleared through the 510(k) pathway

•  AM devices regulated through the same pathways as non-‐AM devices

•  Significant increase in 510(k) cleared devices 2011-‐2012

•  Majority of 510(k) clearances for orthopedics applicaMons

FDA Status of 3DP in Medical Devices

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Common Applications

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Medical Devices are Regulated J

Any 3D Printed Medical Device has to go through same ‘scope of a regulated product’ as non 3D printed medical devices.

(even 3D printed ones) Receipt of materials

Design of product

Premarket testing and

activities

Manufactu-ring of

product

Final inspection/

QC of product

Shipment of product

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Class I

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Class II

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Class III

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What were some challenges you’ve encountered in using 3D prinMng in

a medical applicaMon?

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Its not just about the 3D printer anymore…

The Digital Thread

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We Had to Rethink Design

•  Patient specific design is complex •  Software tools made to handle organic geometries are key

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Haptic Design

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Conformal Design

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Consistency in Manufacturing •  Raw material control •  Calibration •  Environmental controls

(temperature, humidity)

•  Part support •  Post Processing

(removal of liquid polymer / excess powder, light curing, stress relief / HIP for metals)

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Build Orientation of Parts

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Why additive for implants? •  Porous, porous, porous •  Bone ingrowth provides both

better initial and long-term stability

•  Properties close to human bone (avoid stress shielding)

•  With additive methods we create the solid and porous in one integrated step

•  Complexity is free •  Ideally suited for patient specific

#DWwebinar Di Prima, Ma,hew. Presentation: “FDA Technical Perspective on Additive Manufacturing” Additive Manufacturing for Medical. Boston July 2015

Unit Cells of Design •  Design Strongly effects

performance •  Density: overall porosity,

pore size, strut size •  Design is based on unit

cell size and shape

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With 3D printing, how will design of medical devices change?

•  THINK DIFFERENTLY – you are no longer designing based on the confines of a traditional manufacturing

•  Conformal design for the human body will continue to grow

•  The design cycle from idea to product continues to improve Swedish firm Gassling

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THANK YOU!

[email protected]

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3DP IM – What is it?

3DP IM – Where does it fit?

3DP IM – When to Use it?

3DP IM – Customer Stories

3DP IM – How to Use it?

01

02

03

04

05

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http://www.meddeviceonline.com/doc/3d-printed-injection-molding-the-future-of-rapid-prototyping-0001

•  Production grade parts: available for verification and validation testing

•  Accelerate development: 90%+ time savings

•  Highly cost effective: save 60-75% on tooling

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.Medical

John D. Murray President & CEO Concept Laser Inc.

Imag

es c

ourte

sy o

f Con

cept

Las

er

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.1997 – Development of Laser Melting Technology

.1999 – First patent for stochastic exposure

.2000 - Concept Laser GmbH

.2002 – First machine delivery for metal 3D Printing

.2003 – Sales, Marketing and Service structure implemented

.2012 - Concept Laser, Ningbo (China)

.2014 - Concept Laser Inc., Dallas (USA)

Background

www.conceptlaserinc.com

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. Machine type for every application

. Use of Rapid Prototyping up to the integration in the production environment

. Build envelope from small (50 x 50 x 70) to large (800 x 400 x 500) available

. Laser power of 100 watts up to multi laser solutions with 2 x 1 kW

Machine Portfolio


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Materials .20s: Stainless steels .30s: Aluminium alloys .40s: Titanium alloys .50s: Tool steels for plastic injection molding .60s: Tool steels for aluminum die-casting .70s: Tool steels for mechanical engineering .80s: Copper alloys .90s: Stainless hot-work steels .100s: Nickel-based alloys .110s: Cobalt chrome .Special and other alloys available upon request


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Medical Mold Aerospace

Automotive Jewelry Dental

Industries


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LaserCUSING® Process

Imag

e co

urte

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cept

Las

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Material-Efficient

Waste with CNC Machining

Conventional Machining (CNC material)

Material need with additive manufacturing

Waste with additive manufacturing

Metal Additive Manufacturing Process

Imag

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cept

Las

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with metal additive manufacturing

CNC machined bracket

CNC Process

Additively manufactured Bracket with optimized design

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In-Situ Process Monitoring with QMmeltpool . System is integrated into the optical path . Process is monitored by camera systems . Real-Time In-Situ monitoring possible . Highest resolution . Very high detection frequency 10kHz


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QM system: QMmeltpool

Part no. 1: NOT OK. Part no. 1: NOT OK.

Part no. 1: NOT OK

Part no. 30: OK

Part no. 30

Part no. 1


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Specific solutions for medical applications: o  Trauma o  Spine o  CFM (craniofacial microsomia)

Advantages: o  Manufacturing of customized biocompatible

implants or prosthesis with microcellular structure

o  Manufacturing of bone-foams with bioanalog structure to use as bone substitute material

o  Manufacturing of unique or complex serial implants or instruments

o  CE-certified materials for medical applications

Medical


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Tsunami Medical

Design for AM Component Preparation Component Assembling

Component Laser Welding Shine Polishing


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Hip stem implant Manufactured on M2 cusing / prototype manufactured from the material CL 41TI (TiAl6V4 ELI) / LaserCUSING allows the manufacture of implants with unique geometric features, which in turn make new features or functional integration in implants possible. These include macroporous surface structures for an improved bone ingrowth into the implant and volume structures to adopt the stiffness of the implant to the bone. Implant with metal bone „foam“ •  Lattice structure to allow bone ingrowth •  Only possible with additive technology •  Mass production or customized products

Mugeto®


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Implants and Instruments

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Leslie Langnau Moderator Design World [email protected] @DW_3Dprinting

Katie Weiner Vice President of Medical Devices 3D Systems [email protected]

Questions?

John Murray President & CEO Concept Laser, Inc. [email protected]

Gil Robinson Senior Applications Engineer Stratasys, Vertical Solutions [email protected]


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Thank You q  This webinar will be available at

designworldonline.com & email

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