In recent years, the rapid development of additive manufacturing technology in healthcare has led to significant advances in research, drug development and the production of prostheses, implants and medical devices. In the latter case, metal 3D printing in particular has revolutionized the medical industry, enabling highly customized and rapidly produced medical solutions. Furthermore, the use of biocompatible materials, such as titanium and cobalt alloys, guarantees safe and durable medical devices. It also enables more sustainable production by reducing material waste, cutting manufacturing costs and improving efficiency through higher production speeds.
Additive manufacturing now makes it possible to create tailor-made plates, screws and complete prostheses and implants, all perfectly adapted to the anatomical characteristics of each patient. This is made possible by integrating technologies such as 3D scanning, CT and other imaging techniques, with 3D software and 3D printers. The resulting products have proved not only safe, but also, in some cases, more effective, speeding up the patient’s healing process. To explore this topic further, let’s take a look at this recent case study to understand the benefits of using metal additive manufacturing to produce titanium shoulder arthrodesis plates.
3D printing is changing the way medical implants and prostheses are produced
Comparison of Shoulder Arthrodesis Plates Made Using Traditional and Additive Manufacturing Methods
Manufacturers of implants for spinal surgery, neurosurgery and osteosynthesis are encountering numerous difficulties in the production of shoulder arthrodesis plates. These devices are used to resect (a surgical term meaning cut out when referred to a tissue or part of an organ) the humeral head in cases of shoulder ligament injury. However, manufacturing these products using traditional methods remains a challenge, as the design and manufacture of specialized tools is time and resource intensive. In addition, the complex geometry of the parts poses difficulties. In addition to machining, bending operations are often required, but this technology is not very precise and does not guarantee the necessary degree of repeatability.
Eplus3D recently presented the case of an industrial company that used L-PBF metal 3D printing technology to solve precisely these problems. The use of additive manufacturing enabled a fully functional shoulder prosthesis prototype to be produced in a short space of time, significantly reducing prototype development costs.
3D Printing Titanium Plates
Eplus3D’s EP-M260 3D printer was used to produce shoulder arthrodesis plates. This L-PBF metal machine has a print volume of 260 mm × 260 mm × 390 mm, supports single- or dual-laser configurations and can process a variety of high-performance materials, including titanium alloys, stainless steel and aluminum alloys. For the 3D printing of the shoulder arthrodesis plates, the material chosen was VT6 titanium alloy, which has been certified by medical authorities. 3D printing of the parts, which measure 25 cm in length and have a layer height of 30 μm, took around 12 hours.
The EP-M260 3D printer from Eplus3D
Once printing was complete, each product was heat-treated at around 700°C for two hours to remove any residual stress. The print supports were then removed using hand tools, and the parts were finally sandblasted. 3D EP-M260 from Eplus3D
The tapered threads originally envisaged in the product have been deliberately omitted from the 3D model in order to achieve a more accurate cut using traditional machining methods. Indeed, when using L-PBF technology, alternating thermal expansion and contraction can lead to deformation and shrinkage, compromising the geometry and regularity of the thread.
To solve this problem, simple holes were drilled in the cast model, onto which the threads were then executed by CNC or manual machining. This solution produced smooth surfaces and dimensional tolerances in line with the required standards.
As a result, the shoulder arthrodesis plates were produced with great precision and tailored to each patient’s anatomical characteristics. The company found that the process was shorter than with other manufacturing technologies, required fewer resources and materials and produced more accurate results, speeding up patient recovery.
The success of this application is a clear example of how metal 3D printing is revolutionizing the world of medicine. As additive manufacturing advances, we are seeing the introduction of ever more powerful biocompatible materials and cutting-edge techniques that not only simplify processes, but redefine the way we treat patients. This progress has only just begun.
Image Credits: 3Dnatives
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*Cover Photo: 3D-printed shoulder arthrodesis plates (all photo credits: Eplus3D)