additive manufacturing applications in the medical field · source: within, eos, alphaform,...
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Additive Manufacturing – Applications in the medical field EOS GmbH
Stephanie Kochbeck
June 2015
EOS – Applications in the medical field | 2
At Present, 3D Printing is Widely Spread in the Media
Source: EOS
EOS – Applications in the medical field | 3
„Enterprise 3D Printing“ – We Are on the “Slope of Enlightenment”
Source: Gartner (July 2013)
Consumer
3D Printing
Enterprise
3D Printing
The Economist, 2012
Computerworld, 2013
The Economist, 2011
The Economist, 2011
EOS – Applications in the medical field | 4
EOS: Technology and Market Leader for Design-Driven, Integrated e-Manufacturing Solutions
EOS Management
Dr. Adrian Keppler , Dr. Tobias Abeln , Dr. Hans J. Langer, Rudolf Nertinger, Christian Kirner (from left to right)
Family-owned, founded in 1989,
Headquartered in Krailling near Munich, Germany
~ 1600 systems installed worldwide – 40% metal systems, 60% polymer systems
Integrated solution provider for Additive Manufacturing :
Additive Manufacturing (AM) systems
Materials (plastics and metals)
Software
Services
Complete end-to-end solutions: from part design and data generation to part building and post-processing
EOS is committed to: Innovation – Quality – Sustainability
EOS Headquarters in Krailling, Germany
EOS – Applications in the medical field | 5
EOS Additive Manufacturing: Functional Principle
Functional principle for polymer and metal materials. Source: EOS
From a 3D CAD model…
… to complete parts
Application of powder
Exposure by Laser
Lowering of platform
Re-application of powder
Exposure by laser
EOS – Applications in the medical field | 6
Key Benefits of Additive Manufacturing for Medical Applications
Productivity advantage
Cost advantage
Freedom of design
Customization
$
EOS – Applications in the medical field | 7
Individualized parts
Patient-/ Surgeon-/ Procedure-specific adaptations
Cost efficient small series up to "lot size one"
Productivity advantage
Cost advantage
Freedom of design
Customization
$
Key Benefits of Additive Manufacturing for Medical Applications – Customization
Source: CEIT, Novax DMA, FHC
Permeable skull implant made of titanium
EOS – Applications in the medical field | 8 Source: Within, EOS, Alphaform, Instrumentaria
Productivity advantage
Cost advantage
Freedom of design
Customization
$
Key Benefits of Additive Manufacturing for Medical Applications – Freedom of Design
Lightweight parts
Complex components
e.g. porous surfaces
Lattice structure hip cup design for improved osseointegration
EOS – Applications in the medical field | 9 Source: Hettich, S&N
Productivity advantage
Cost advantage
Freedom of design
Customization
$
Key Benefits of Additive Manufacturing for Medical Applications – Cost Advantage
Reduced waste
No tooling cost
Reduced assembly and logistics cost
Reduced inventory
Faster surgeries Pre-operative planning Patient-matched instrumentation/implants
Visionaire patient matched instrumentation by S&N
EOS – Applications in the medical field | 10 Source: EOS
Productivity advantage
Cost advantage
Freedom of design
Customization
$
Key Benefits of Additive Manufacturing for Medical Applications – Productivity Advantage
Rapid prototyping and serial applications
Fast feasibility feedback of virtual models
Haptic feedback
Shorter time to market
Mass customization
90+ systems (M270)
Up to 450 units in 22h
Around 5 million
units produced/year
Dental crowns & bridges in CoCr
EOS_Company-Presentation.pptx | EOS | 11
70+ Additively Manufactured Medical Devices Cleared Through the 510(k) Pathway in the US Patient matched implants
Skull plate
Maxillofacial implants
Knee implants
Patient matched surgical guides Orthopedic devices Dental
iTotal® TKR by ConforMlS VSP® by Medical Modeling Novation Crown, Exactech e-DENT Temporary Resin, DeltaMed GmbH
FDA: „AM devices are regulated through the same pathways as non-AM devices. The FDA regulates medical devices based on intended use, indications for use, and technological characteristics within a risk-based framework regardless of specific manufacturing process.“
Craniofacial
Knee
Ankle
Hip cups
Spinal cages
Knee trays
Temporary bridges
Reconstructive surgery support
Source: FDA – Presentation during RAPID workshop on May 18, 2015 in Long Beach, USA.
http://www.accessdata.fda.gov/cdrh_docs/pdf12/K122870.pdf
http://www.accessdata.fda.gov/cdrh_docs/pdf12/K120956.pdf
http://www.accessdata.fda.gov/cdrh_docs/pdf10/K102975.pdf
http://www.accessdata.fda.gov/cdrh_docs/pdf10/K102776.pdf
EOS_Company-Presentation.pptx | EOS | 12
… Will Ensure Constantly High Quality Parts!
System
Process Material
Part quality
Aff
ects
Dependent of each other
The Well Balanced AM Triangle…
EOS – Applications in the medical field | 13
Various production factors influence the final part quality
Complexity of AM production process
Source: Expert interview, Roland Berger
EOS – Applications in the medical field | 14
AM is Competing With Traditional Production Methods, but Most Often: it is Complementary Most advantageous production method, depending on quantity and complexity
With increasing productivity and reliability, AM becomes more and more competitive. At the same time AM will continue to be a complementary process to traditional manufacturing.
AM enables new geometric shapes at virtually no additional cost
Source: Arcam annual report 2014; Roland Berger
EOS – Applications in the medical field | 15 Source: MTU presentation in Milano, Italy in September 2012.
Users in the Aerospace Industry Use a Stepwise Approach Towards AM Learnings from the aerospace industry
EOS – Applications in the medical field | 16 Source: MTU presentation in Milano, Italy in September 2012.
Experience with Low Risk Test Parts Helped to Build Up Trust Learnings from the aerospace industry
EOS – Applications in the medical field | 17 Source: MTU presentation in Milano, Italy in September 2012.
In the Next Step, Existing Parts Are Produced Additively to Manage Risk Learnings from the aerospace industry
EOS – Applications in the medical field | 18 Source: MTU presentation in Milano, Italy in September 2012.
After Experience and Trust is Gained, the Full Potential of AM is Being Exploited Learnings from the aerospace industry
EOS – Applications in the medical field | 19
Additive Manufacturing Provides High Value for Medical Applications
The laser sintering technology is ready for operation – large OEM start using it as production technology
Customization and freedom of design as well as cost and productivity advantages are key differentiators
Focus on the complete solution chain – mission critical is design and post processing
Summary
EOS – Applications in the medical field | 20 Source: Materialise
Nose Implants
Additive Manufacturing – the manufacturing technology that will change the medical world!