alloy metal powders for dental applications meetings/29march...schematic illustration of a slm...

30/03/2007

Sandvik Osprey / BASF Meeting – 14 March 2006

29th March 2007

Innovations in Materials and Manufacturing of Denta l Devices

Dr Martin Kearns Sandvik Osprey Ltd., Red Jacket Works, Milland Road, Neath, SA11 1NJ

www.smt.sandvik.com/osprey

Alloy Metal Powders for Dental Applications

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Introduction

� Sandvik Materials Technology & Sandvik Osprey

� Sandvik Bioline

� Range of products

� Powder Metallurgy

� Technologies: MIM, SLM, Coating, HIP

� Powder production

� Benefits of net shape manufacturing

� Case Studies

� Dental & Medical components

� Current trends

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� High quality wrought alloys in bar, wire,

strip, profiles and tubular products.

� Bio-compatible, with excellent corrosion

resistance and exceptional strength suitable

for medical implants, fracture management

systems, surgical and dental tools and instruments

� Wide variety of alloys (Stainless steels, Titanium and Cobalt alloys) and product forms supported by advanced R & D facilitie s

� Special net shape powder products from Sandvik Ospre y

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Sandvik Bioline stainless and special alloys are well suited for various dental applications such as -

Dental burrs & drillsFiles & reamersBroachesInter-dental brushesScale/tartar removersFixture driversDental implants

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Trends in Metal Prices Feb 2006-March 2007Ni, $/MT

10000

50000

Mo, $/kg

85

50

Co, $/lbCr, $/MT

7000

5800 12

32

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Conventional Cast / Wrought / Machine

Melting

Cast

Forge

Roll/Extrude/Draw

Machine

Pickle/Re-machine/grind

Finished shape

Heat treatment

Scrap.. Ends, runners, risers

Scrap.. Forging flash

Scrap.. Edge trim, pipe defects

Scrap.. Swarf, turnings, chips

‘Fly-to-buy’ ratio for some Products (e.g. Ti alloys)can be <10%

Scrap.. Grindings, sludge

Hard materialsdifficult to machine

Expensive thermo-mechanicalforming/ inter-anneals

Slow-cool, segregation

Distortion

Surface damageembrittlement

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Powder Metallurgy Routes

Melting

Atomise

Sieving/sizing

Die Pressing

Finished shape

Heat treatment

‘Scrap’.. Melting losses

Scrap.. Oversize remelted

High materials utilisation throughout

Laser deposition MIM Net shape HIP

Machine off orpickle canister

Recyclespruesrunners

Recycleoverspray

Finish grindor coining

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Powder Metallurgy Forming Routes: size & number of parts

PartWeight

grammes

Number of Parts

10 102 103 104 105 106

1

1

10

102

103

104

105

106

107

0.1

RapidPrototypes

1 tonne

1 kg

MIM

HIPpedParts

Uniaxial Pressings

MIM

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� 5 powder production lines

� High volume production lots - 3000Kg

� Experimental lots – 20kg

� Nitrogen & Argon atomising

� Powder sizing by ultrasonic sieving

and air classification.

� International & customised alloy

specifications

� Standard & tailored powder size ranges

� Size & chemical analysis in-house

The Powders Group

Sandvik Osprey / BASF Meeting – 30 October 2006

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SEM Images of MIM Powders

� Gas atomised alloy powders

� Spherical shape

� Low oxide / impurity levels

� Good flow & mixing characteristics

� Refined, homogeneous microstructures

� Isotropic properties approaching

those of wrought products

� Available in a wide range

of alloys and size ranges

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Particle Size Rangesfor different fabrication methods

Filters & Foams

Electron Beam Melting

Press & Sinter typical

Hot Isostatic Press

Selective Laser Melting

Cold Spray

MIM

Coatings

MicroMIM

Fabrication Method 50 100 1500 Size Microns

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MIM - Particle Size Distributions

� - 38 micron (Sieved)

� - 32 micron (Sieved)

D10 3.5 – 5.0 microns (ave. 4.3 microns)



� 80% -22 microns (Air Classified & Sieved)




� 90% -22 microns (Air Classified & Sieved)




� Finer Grades; 90% -16 microns & 90% -10 microns

� Micro – MIM 80% -5 microns

Increasingprecision

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Process

Sintering

Metal Metal powder BinderBinder

Mixing/ Kneading

Injection Molding

De-binding

Secondary Operations

Metal Injection Process Steps

Batch sinterfurnace

InjectionMouldingMachine

High shearMixer

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� Stages in MIM processing

Feedstock(powder+ binder mix)

‘Brown part’after solventdebindering

Injection-moulded‘Green part’

Finished densesintered part

Metal Injection Moulding Process Steps

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Relative cost vs shape complexity

Low Medium High

Unitcost

Shape Complexity

Machining

MIM

Press &Sinter

Casting

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MIM Proposition

Cold ForgingEliminate secondary

processingMIM

Coverage

Die CastingMaterials Flexibility

Investment CastingDimensional Precision

MachiningComplex shapesDifficult materials

Powder MetallurgyBetter strengthNo finishing

• MIM offers a rangeof advantages overother manufacturingmethods.

• Ideal for high volumeManufacture of smallIntricate components.

• Combination of highPrecision, goodmechanical propertiesand flexibility in materials.

• Short development time- 10 weeks from design to manufacture

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MIM Capabilities & Tolerances

Investment Cast MIM

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MIM impact on orthodontics� Orthodontics is a $700million industry worldwide (e st. $130M in

MIM parts)

� The brackets used are small and extremely complex i n shape

� Drive to make even smaller, less visible with thinn er walls & blind pockets.

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MIM for Orthodontic Brackets

� ‘Old’ Investment Casting technology� Injection mould pattern for each individual bracket in polymer, assemble in to “trees” and

investment cast

• 7 process steps

• production time = 30 days

• Scrap rate = 90%

� MIM technology� Injection mould, de-bind and sinter

• 3 process steps

• Production time = 2 days

• Scrap rate < 5% (sprues and runners are recycled in-house)

• No need for secondary machining & deburring.

• 0.1g per part: metal powder cost ~0.2p; manufacturing cost 30p; selling price through distributor ~50-100p; selling price to dentist 150-500p

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Practical benefits of MIM

� Benefits -

� Faster processing time

� Smaller inventories

� Reduced lead times

� Overhead reduction

� Difficult geometry made easy

� Higher quality at lower cost

� Virtual elimination of scrap and hence highly energ y efficient

� Sandvik Osprey has, in conjunction with its custome rs, developedpowders in many different alloys for this sector.

� This includes low nickel variants for patients who display nickel sensitivity.

30/03/2007


Dental/Medical Sector by Alloy Type

� F75: most common alloy for implants/orthodontic bra ckets (CoCrMo)

� 17-4PH precipitation hardening stainless steel for orthodontics &

medical instruments (FeCrNiCuNb).

� Ni-free stainless steels to avoid sensitization (in cluding ‘Panacea’

(FeCrMn base system).

� 440C & 420 Ferritic stainless steels for instruments (FeCrMoC).

� Future specialist products? Ti powders/NiTinol Powde rs

30/03/2007


Dental Applications

Introducing Carriere LX™. The innovative new passive self-ligatingbracket system.

� Features a simple locking mechanism located in the bracket face.

The Carriere LX opens with an instrument and closes securely manually enabling quick and easy archwire changes an d faster treatment time.

� Low profile self-ligating bracket provides greater p atient comfort. A micro-etched bonding base offers increased bond s trength.

30/03/2007


Carriere Distalizercourtesy MPIF, World Class Technology

Description: a complex design in two pieces: 1. A posterior pad with a socketand an interior rod with a ball on one end and 2. A pad with a hook on top at the other end. The ball is pressed into t he socket in the posterior pad to make the final assembly, which com es in three sizes, each with a left - and a right-hand version. Made from a nickel-free stainless steel, the parts are formed t o a density of 7.6 g/cm³ and exhibit a yield strength of 550MPa, an ult imate tensile strength of 670MPa, and a 22% elongation.

Description: The system consists of multiple parts made from 17- 4PH stainless steel. The parts have an ultimate tensile strength of 840MPa and a yield strength of 720MPa. Elongation is 10% and the heat-treated hardness range is 38–42 HRC. The heat-treated ultim ate tensile strength is 1300MPa and the heat-treated yield stre ngth is 1120MPa. The tube system was first introduced in the all-met al Damon self-ligating orthodontic appliance. When in full product ion, this application will total more than 12 million parts a nnually.

Damon 3 Molar Buccal Tubecourtesy MPIF, FloMet, Inc.

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Thornton Adjustable Positioneralleviates sleep apnea/snoring

The TAP® is a medical device that treats sleep disordered breathing. It alleviates snoring and sleep apnea by holding the mandible forward during sleep to prevent the tongue and soft tissue of the throat from collapsing into the airway. Based on the same principle as cardiopulmonary resuscitation (CPR). The airway must be open to allow air to pass through the throat.

The metal components in the TAP® are madefrom 316 surgical stainless steel. Outer shellsare thermoplastic orthodontic polycarbonate

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Micro - MIM� Micro- MIM takes MIM to another level where Osprey p owders less than

5 microns in diameter are used to produce “micro” pa rts

� Review of MIM papers presented at the conference.� Micro Metal Injection Moulding - Quality Assurance i n Series ProductionAstrid Rota, Philipp Imgrund, Lutz Kramer, Ralf Mey er, Janne HaackFraunhofer IFAM, Germany

316L stainless steel ear implant

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Rapid Prototyping/Manufacture

� Selective Laser Sintering

� Infiltration

� Selective Laser Melting

� Electron Beam Melting

� Direct Metal Deposition

� Laser Engineered Net Shapes

� Metal Powder Screen-Printing Schematic illustration of a SLM machine.

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Medical Applications � Scanning & Digitizing

� Rapid Machining Centres

� Selective Laser Melting for Dental Applications

� Scanning & Digitizing

� CoCrMo (F75) powder products are now CE Marked

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Selective Laser Melting- an Emerging Technology

� Biomedical applications

• Orthopaedic implants, joint implant prostheses, pos t-tumour bone reconstruction all using structures which mimic hum an bone

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Electron Beam Prototyping

Using CT scan data, it is possible to build custom designed

implants that perfectly match the shape of the pati ent’s bones.

Arcam has received an order from an Italian manufacturer in the biomedical field. The system will be used for volume production of orthopaedic implants. (Q4 2006)

Maxillo-facial reconstructionF75 and Ti alloy products

Sequential Electron Beam melting of powder bed

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Quick-fit connectors

for oil pipe-lines

• Full range of stainless steel and cobalt alloy powders for critical applications.

• Option for fine particle size to reduce defect size.

HIP Powders

Extruder Barrel Coating

Sinter Beads

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� Commercially Pure Titanium (MIM-Ti)� 0.2%Yield Strength 420 MPa

� Tensile Strength 500 MPa

� Elongation 20%

� Hardness (HV) 190

� Titanium Alloy (MIM-Ti-6Al-4V ELI)� 0.2%Yield Strength 700 MPa

� Tensile Strength 800 MPa

� Elongation 15%

� Hardness (HV) 300

Mechanical Properties of Ti-MIM

Data courtesy of TiJet Medizintechnik, Germany

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� Cochlea implants

� Heart tri-valve

� Orthopaedics

� Hips, knees, studs

� Small joints.. Fingers, toes

� Dental.. Pegs

� Porous structures for bone ingrowth

� Maxillo-facial.. Mandible products

� Tools.. Drills & burrs, reamers, forceps, scissors

� Mini-screws in Ti for high precision crown implants that allow bone in-growth

� Excellent biocompatibility but concerns over availability of affordable, good quality feedstock & dificulty of controlling MIM process reproducibly with Ti.

Titanium MIM

courtesyTiJet Medizintechnik

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New developments

� MicroMIM powders; 80% -5 microns giving finer resolu tion

& enabling further miniaturisation of components

� New alloy systems – Ni-free ranges: alternatives to Panacea

� MIM for in vivo implants – bone repair

� Alloys with controlled modulus for more comfortable orthodontics

� Ti alloy powders

� NiTinol Powders

� Combination of powder technologies to make hybrid s tructures

30/03/2007


Conclusions� MIM has overtaken investment casting of orthodontic s brackets with better

precision, lower cost and greater opportunity for m iniaturisation.

� ~7% by volume of the MIM market today is in medical & dental applications but the % is greater in value terms. Primary market is N.America.

� Key alloys are F75 (CoCrMo), 17-4PH and 316L (ELI) plus low Ni stainless steels. Properties equivalent to wrought can be ach ieved by MIM.

� Cost of metal powder is a small fraction of finishe d part cost. Rapid expansion of MIM possible through greater awareness of advantages.

� Growth of Ti in MIM hampered by cost and complexity of processing.

� CAD to Laser and CAD to Electron Beam processes are being adopted more widely for manufacture of bespoke caps, bridges etc .

� Control of particle size distribution to achieve go od flow and therefore good part conistency and also to improve on resolution of finished parts.

30/03/2007


Metal Powder for Medical & Orthodontic Applications

Sandvik Osprey Ltd is part of the US$10 billion Sandvik Group, with 40,000 employees operating in more than 130 countries. The Sandvik Group is a high technology global engineering group with advanced products marketed worldwide. As a leading producer of metal powders for high performance end uses, Sandvik Osprey has developed a range of gas atomised metal powders specifically

designed for medical and orthodontic applications. These include applications in orthodontic brackets, orthopedic implants and surgical instruments. Manufacturing techniques exploit the latest high precision and net shape powder metallurgy processes including:

• Metal Injection Moulding (MIM) • Selective Laser Sintering (SLS) • Selective Laser Melting (SLM) • Electron Beam Melting (EBM) • Laser Engineered Net Shapes (LENS) • Sintered Metal Beads (SMB)

The Gas Atomised Powder Range includes: Cobalt Alloys -

• ASTM F75 (Co 29Cr 7Mo) • ASTM F90 (Co 20Cr 15W 10Ni) • MP35N UNS R30035

Stainless Steels -

• 17-4PH - UNS S17400 • 316L - UNS S31603 & ISO 5831-1 • 440C - UNS S44004

These powders have a spherical morphology and therefore excellent

flow characteristics and are available in a wide range of particle size distribution, from < 5 µm to < 250 µm powder particle diameters. The powder size distribution is tailored to the application requirements, be they fine powders for MIM and Rapid Prototyping, or coarse powders for Coating or Hot Isostatic Pressing (HIP) applications. They are manufactured using the highest quality raw materials, including vacuum cast feedstock and handled within a clean room environment with dedicated equipment.

Recommendations are for guidance only, and the suitability of a material for a specific application can only be confirmed when the actual service conditions are known. Continuous development may necessitate changes in the technical data without notice.

SANDVIK OSPREY LTD

Red Jacket Works, Milland Road, Neath, SA11 1NJ, United Kingdom Tel: +44 - (0)1639 - 634121 Fax: +44 - (0)1639 - 630100

E-mail: [email protected] Website: www.smt.sandvik.com/osprey

30/03/2007


Sales & Service

[email protected]

www.smt.sandvik.com/osprey

alloy metal powders for dental applications meetings/29march...schematic illustration of a slm...

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