your partner in additive manufacturing - biotinet › downloads › 2nd workshop belgium ›...

2 n d B i o T i N e t Wo r k s h o p , 2 0 1 2 - 0 3 - 0 6

Your PARTNER in Additive Manufacturing

Dental and surgical applications of Additive Manufacturing: from

research to daily business Dr. Ir . Peter Mercelis

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© LayerWise NV, all rights reserved © LayerWise NV, all rights reserved

Presentation overview

About LayerWise

Introduction to Additive Manufacturing

AM of dental implant prostheses and medical implants

From R&D to business

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About LayerWise 3

Who We Are LayerWise was incorporated in 2008 as a spin-off from the University of Leuven

Dept. Mechanical Engineering & Dept. Metallurgy and Materials Engineering

Started by Peter Mercelis and Jonas Van Vaerenbergh

Unique focus on Additive Manufacturing of metals


LayerWise 4

Organization LayerWise

NV

Industrial

prototypes

engineering

series production

Medical

patient specific medical implants

Dental

patient specific dental prostheses

R&D

technology

material

software


Introduction to Additive Manufacturing 5

Basic

principles

Layer-by-layer manufacturing of 3D objects

Selective Laser Melting = AM technology using a focused laser beam to melt thin layers of powder metal



Basic

principles

Layer-by-layer manufacturing allows unlimited shape complexity

Fully digital production technology, directly from CAD



Materials and

specifications

Materials:

Stainless steels (316L, 17-4 PH, etc.)

Hardenable steel

Bronze based alloy

Titanium (pure, Ti6Al4V, …)

Cobalt-chromium alloys (ASTM F75)

Inconel

Aluminium

…

Specifications

Maximum build volume 250x250x200 mm

Density 100 %

Typical part accuracy* ± 50 µm

Typical surface roughness* # 5 µm Ra – 40 µm Rz

Minimal wall thickness 0.15 mm

Minimal feature size 0.20 mm

* dependent on part geometry # can be improved by LayerWise SILC treatment



Melting

Characteristics

Resulting relative density up to 99.98 %

Ti6Al4V


AM of dental implant prostheses 9

Result of R&D project @ K.U.Leuven; collaboration between dept. Mech. Engineering (Prof. JP Kruth – Dr. Ben Vandenbroucke) and dept. Prosthetic Dentistry (Prof. I. Naert)

Basic research started in 2004, finished in 2008

Research summary:

Proof of concept

Parameter and property optimization for Ti6Al4V and dental CoCrMo;

SLM optimization

Mechanical characterization

Chemical characterization

Development of model scanning;

Tactile scanning to measure implant positions

Laser triangulation to measure dental wax-up

Testing of design software

5 clinical cases


Original workflow 10

Ditizing; tactile

scanning +

laser scanning



Digital bridge

design; theory



Digital bridge

design;

practice



Manufactured

dental bridges



Further

developments

Further developments @ LayerWise: Parameter and property

optimization Build rate improvement Surface roughness improvement Density improvement Mechanical property improvement

Development of model scanning; from tactile scanning and laser triangulation towards fringe-projection systems



Further

developments

Integration of CNC controlled finishing of implant connections

Verification of total process accuracy

Development of design software

Development of implant connection library; currently 100+ connections



Further

developments

Development of database software for order processing

Hiring people (engineers, dental technicians, salesforce)

Marketing

Pricing

…



Further

developments

Additional development:

2 years time

Large investments

Commercially available since 2010

© LayerWise NV, all rights reserved

Medical applications: dental prostheses 19

Implant supported dental prostheses Individual, custom design

Digital modeling and production

Higher accuracy; < 20 microns at implant interface

Improved surface retention

Gingival sealing edges = SealWise concept

Perfectly compatible with immediate loading protocols and intra-oral scanning

Less manual work

Less consumables

Patented technology by LayerWise



SealWise connections for improved sealing at gingival level



Current service model 23

Future model; intra-oral scanning in dental practice


Medical applications: custom implants 24

Custom

Implants

Patient-specific modeling of the implants; Based on medical

imaging data Pre-operative planning,

design, and production Trough partner

companies In close collaboration

with the surgeon!

Mimimal invasive two-piece zygoma implant, LayerWise NV



Total mandible

reconstruction Total mandible reconstruction



Total mandible

reconstruction



Custom

implants Custom acetabular

implants

Custom cranial implants

courtesy of Mobelife NV


Medical applications: standard implants and instruments 29

Implant and

instrument

manufacturing

Window of interest:

Small to medium sized implants: CMF, trauma fixation, small articulation prostheses, bone screws, etc.

Interfacing with standard components (e.g. locking screws, PE inserts, etc.)

Complex instruments


Medical applications: standard implants and instruments 30

Implant and

instrument

manufacturing

Ideal for small to medium batch sizes

Parallel manufacturing of different designs

Very short lead times

Allows reducing stock levels of implants and instruments!


From R&D to business 31

General

observations

Time-to-market Make up a clear overview of work to be done:

Man months External testing and subcontracting Allowed development time! => Necessary work-force and budget

External verification! Need to work according to relevant standards Testing done by certified testing laboratory


From R&D to business 33

General

observations “Spin-off” title

Is very useful in the to gain visibility and to approach the academic world

May be a handicap in a business-to-business context …


Contact details

LayerWise N.V.

Kapeldreef 60

3001 Leuven

Belgium

tel: +32 16 29 84 20

fax: +32 16 29 83 19

www.layerwise.com – www.dentwise.eu

[email protected]

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