workaholics pim dental implant project
TRANSCRIPT
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Workaholics AnonymousKendal HanelBryant Pham
Konstantin IvanovHoang PhamRobert Scult
Anthony Tilley
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Problem StatementDental implants are made
out of machined metalsTop component suffers
excessive wear
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Material Selection CriteriaAvailable particle size and shape for micro-
feature PIMBiocompatibleWear ResistantLow oxygen and carbon content
Final Decision Post Implant – CP Ti Grade 1
Screw Hate – Al2O3
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Powder SpecificationsAP&C Advanced
Ti Spherical Sieving Apparent Density
0-25um 32% 2.55 25-45um 65.5%+45um 2.5%
Inframat Advanced MaterialsAl2O3
Spherical Particle Size Apparent
Density3-4um Avg. 3.97 g/cm3
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Manufacturing Process Mix powder Polypropylene, paraffin wax, and stearic acid binder at 65%
solids loading PIM using Archimedes screw heated barrel Immerse in heptane at 60°C Second stage Argon sweep gas for Titanium at 450°C max Vacuum sinter at 1250°C for 3 h for Titanium Finish Titanium with hot isostatic pressing Sinter at 1400°C for 2 h for Alumina
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InspectionVisual and SEM (appearance)
Dye penetration (surface cracks)
Core X-ray (inner core defects)
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Critical FunctionImproving wear resistance of the componentBiocompatibility of componentRemoving all machining stepsMaterial selection to improve propertiesHigh wear resistance from AluminaTitanium & Alumina fit biocompatibility
requirements
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Market Shares Estimated $3.4 Billion in implant sales a year & growing at 10%/year“American Academy of Implant” estimated 3 million people with implants and 500k increase/year in US69% of adults (age. 35-44) have lost at least 1 permanent toothBy age 74, 26% of adults will have lost all of their permanent teeth.Europe ½ global market, while North America 2nd largest regionGrowth in the Asia/Pacific region being driven by China & is expected to increase the global size in coming years.15% Market Share @ 3 Implants/person
225,000 units/year
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Failure CriteriaDoes not fit dimensional toleranceUnnecessary secondary finishing operationsHigh oxygen or carbon contentLow volume productionNo profitUnacceptable defects
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Equipment CostWittmann Battenfeld Molding Machine + Robot
$130,000Scott Turbon Mixer Inc. Double Planetary Mixer Ipsen Vacuum Debind/Sinter Furnace
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Production Cost$15,000 Mold made in ChinaHIP contracted to Pressure Tech Inc. @ $2000/cyclePart Volume
Post 0.173 Cap 0.128
0.73179 g/unit Ti @ $150/kg0.5052445 g/unit Alumina @ $26/kg$0.15/unit material$0.23/unit processing
$0.38/unit total
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References http://www.wittmann-ct.com/lib/f_dbstream.php?tn=tab_file&fd=file&mt
=application/pdf&id=1079&hxfile&f=YearEnd2012.pdf
http://www.dental-tribune.com/articles/business/americas/11737_dental_implants_market_expected_to_double_by_2018.html
http://www.raymor.com/apc/products/titanium/#gr-1_0-45
American Association of Oral and Maxillofacial Surgeons
http://www.pressuretechnology.com/hot-isostatic-pressing.php
http://www.ncbi.nlm.nih.gov/pubmed/17257912
http://www.sciencedirect.com/science/article/pii/S0965997809001367
http://link.springer.com/article/10.1007%2Fs11837-011-0036-z