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3D Printed Implant

3D printing which is also known as additive manufacturing is one of the most useful technologies of this era.  3D printing finds application in the medical industry as well. It is used extensively to manufacture 3D implants. Metal 3D printing overcomes many of the limitations of traditional manufacturing methods.  This blog will discuss the 5 most used 3D printed implants.

Cranial implants:

Cranial reconstruction can be required to restore the skull contour. It is also helpful in protecting the intracranial structures and also in normalizing cerebral hemodynamics. 3D printed patient-specific cranial implants help in providing the exact symmetry. Along with this, the original aesthetics are also maintained. Apart from this, customized 3D metal printed implants give strong and stable protection which is always better than any available implants. Traditional methods of producing implants may lead to results which could be aesthetically unsatisfying. And hence, it is advisable to opt for 3D printed implants.

Hip implants:

Patient-specific 3D printed implants are also widely used to replace deformities in the hip region. 3D printing has revolutionized hip replacement surgeries. These implants help in replacing the bone lost to conditions like osteoporosis, bone cancer or injury. The patient’s medical scans are used to design an accurate preoperative 3D plan which includes a detailed outline of the procedure. It also gives an overview of the screw positioning and lengths.

Vertebra implants:

For a patient suffering from something like ankylosing spondylitis which is serious arthritis that causes inflammation of the vertebrae, 3D printed implants could be the best possible solution. Such conditions may cause the patient to lose mobility, making everyday activities very difficult. Patient-specific 3D printed implants can help replace the damaged vertebrae. These innovatively designed 3D printed spine implants have various lattice structures which help faster bone growth through a scaffold-like structure and faster osteointegration.

Metal 3D printing or additive manufacturing has indeed revolutionized the medical industry. 3D incredible with its passion for helping people is one of the top manufacturers of all kinds of patient-specific 3D printed implants in India.

Orbit Reconstruction implants:

Orbit reconstruction has been considered as quite a complex procedure since orbit anatomy is very complex, surrounded by vital organs like the brain, eyes, sinus cavities, etc. 3D metal printed customized implants help surgeons to reconstruct deformities close to its original anatomy to give excellent relief.

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3D printing which is also known as additive manufacturing is one of the most useful technologies of this era. Its benefits are being readily embraced with real-life applications being developed almost every day.

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3D printed implants are making the surgeries more efficient, faster recovery and the patient’s quality of life significantly better but all of this comes at a huge cost. As compared to traditional implants, 3D printing makes use of various resources and expensive machines

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Patient specific implant manufacturing or 3D metal printed PSI offers better anatomic fit, reduced operating time, and satisfying aesthetic results compared to conventionally manufactured PSI.

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3D printing is becoming a great asset to the medical industry (Mandible Implants with 3D Printing) especially for facial injuries which are very complex and treating them is a big challenge for any surgeon.

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With evolving technology, 3D printing is becoming a great asset to the medical industry (Mandible Implants with 3D Printing) especially for facial injuries

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The progress and growth of 3D printing applications within the medical industry havebeen and continues to be, exponential. Amongst all the current and potential applications of this technology, the medical applications of 3D printing are the most talked about and written about.

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3D Metal Printing Technology

The major reason behind this growth might be because it is essentially the most fundamental application of any technology, in that it is being used to save, extend and/or change lives for the better. There are various medical devices produced by using the 3D printing technology such as orthopaedic and cranial implants, surgical guides, dental restorations such as crowns, and custom-made external prosthetics.

The progress and growth of 3D printing applications within the medical industry have been and continues to be, exponential. Amongst all the current and potential applications of this technology, the medical applications of 3D printing are the most talked about and written about. Here we will discuss the applications, progress, and use of 3D printing in medical devices.

· Growing demand for patient-specific implants Another reason for the exponential growth of 3D printing in medical devices has been due to the increased demand for customised implants. Proper use of these implants is vital due to the critical nature of placing these devices within the human body to fulfil the function of body parts that no longer work and cannot be repaired, whether as the result of any injury or worn out through longevity. In neurosurgery, the use of these implants and prostheses is very important, as skulls have irregular shapes and it is hard to standardize a cranial implant. Across the medical field, considerable research is being undertaken into the development of superior and cost-effective medical implants.

 · Huge Industry scope The impact of 3D printing in the medical industry is well-documented.The medical field has been using 3D printing technology to drive innovation in almost every aspect of the industry, spanning everything from medical models and prototype parts to 3D printed assistive devices like prosthetics and wheelchairs. The implications of 3D printed medical devices are so significant that they could result in less expensive and more accessible healthcare. 3D printed medical devices can often be produced faster and less expensively than their traditionally manufactured counterparts, giving users more value for money without sacrificing quality. Due to this very reason, we can expect to see the medical field benefit heavily from existing and future innovations in medical 3D printing.

· Patient-specific anatomy models One of the most prevalent applications of 3D printing today is clearly the production of patient-specific medical models in preparation for surgery. 3D printing helps in creating patient-specific organ replicas that surgeons can use to practice on before performing complicated surgeries. The use of 3D-printed models for surgical training is also preferable than training on cadavers, which are costly and not readily available.

·  External Prosthetics The medical field has been using 3D metal printing to produce prosthetic limbs that are customized to suit and fit the wearer. The production of low-cost prosthetics has accentuated the use of 3D printing a lot more. The use of 3D printing significantly speeds up the process and it also creates much cheaper products that offer patients the same functionality as traditionally manufactured prosthetics.In orthopaedics, a clear and persistent problem always exists, where standard implants are often not sufficient for some patients, particularly in complex cases. 3D printing solves this problem effectively by quickly producing customized prosthetics.

Surgical     Guides     A surgical guide is a medical device that is used to accurately assist in the     immediate placement of an implant in the bone structure. It assists the     surgeon to perform the clinical application of drilling implants into the     bone with optimal accuracy by replicating the exact surfaces of the     patient’s oral situation. After placing the surgical guide on the     patient’s jaw, it uses sleeves to help guide your surgical instruments     and, if appropriate, your implant, accurately to the position you have     specifically planned.

 Conclusion: The applications of 3D printing in medical devices are increasing rapidly and it is revolutionizing the health care industry. In the coming years, it is expected that this technology would be making more and more advancements.

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3D Printing Technology - 3D Incredible

The 21st century has witnessed a significant amount of progress in terms of technology and innovations. Innovative manufacturing techniques coupled with cutting-edge technological advances have certainly made a strong impact on the manufacturing sector. One of the most disruptive technological advances in the last couple of decades has been the introduction of 3D printing technology to the automotive sector. In addition, the demand for additive manufacturing in the

automotive sector is growing owing to the various benefits of metal additive manufacturing.

3D Incredible is one of the most successful metal 3D printing technology in Pune. We excel at offering the best metal additive manufacturing services at affordable prices. In addition, we have a state-of-the-art manufacturing facility equipped with modern and highly advanced 3D metal printers for all types of applications.

Future of 3D printing technology in the automotive sector

It is safe to say that 3D printing is making a significant amount of impact in the automotive sector. Additive manufacturing, 3D printing, stainless steel 3D printing, aluminum 3D printing, are emerging technologies that are slowly making their way into the automotive industry. In addition, the scope for fresh developments and innovations in the automotive sector is on the rise owing to the introduction of 3D metal printing. However, one of the biggest factors that would eventually drive the demand for 3D printing in the automotive sector is its ability to solve issues related to mass production.

3D Incredible is one of the leading 3D metal printing companies in Pune. We offer the most effective and reliable 3D printing solutions to help our clients manufacture complex parts at a rapid pace in a cost-effective manner. Our team comprises of the best engineers and experts who have a rich understanding of the 3D printing technology.

Let's take a closer look at the relationship of 3D metal printing and the automotive sector

Why 3D printing technology for the automotive sector?

1. Mass production

Typically, in the automotive sector, the production volume is very high. Traditional methods could potentially end up being tedious and time-consuming. However, 3D printing technology which has been largely used as a prototyping solution in the automotive sector has now become a solid alternative for several automotive manufacturers for mass production. With advances in technology, the speed at which the 3D printers print has significantly increased; thus proving to be an effective solution for mass production for multiple medium-sized manufacturers.

2. Pre-production

Additive manufacturing has arguably been the most disruptive in this area when it comes to manufacturing. Due to additive manufacturing, the production of low-cost rapid tooling for thermoforming, jig and fixtures, and injection molding has become cost-effective. In addition, metal 3D printing has significantly helped manufacturers to manufacture automotive parts at a rapid pace.

3. Customization

In the automotive sector, manufacturers are constantly seeking different ways to enhance the overall performance of a vehicle. In order to achieve that, it is important that the various parts that are used are highly reliable and of the highest quality. With the help of 3D printing, manufacturers can modify or customize the different parts required to manufacture a vehicle according to the requirement. Hence, 3D printing in medical is playing a crucial role in the development of high-quality and robust automobiles.

3D metal printing technology and the automotive sector

As mentioned previously, 3D metal printing or additive manufacturing has gained popularity in the automotive sector. Owing to the capabilities of 3D printing, in the current scenario, one can easily manufacture products that are safe, reliable, robust, and cost-efficient. In addition, the manufacturing costs and production time has significantly reduced due to additive manufacturing. The 3D printing technology has disrupted the automotive sector and increased the overall efficiency and productivity right from the manufacturing floor to the design part.

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There are multiple benefits of manufacturing patient specific implants using 3D metal printing for the surgeons as well as patients. Patient specific implant manufacturing or 3D metal printed PSI offers better anatomic fit and many more...

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The progress and growth of 3D printing applications within the medical industry havebeen and continues to be, exponential. Amongst all the current and potential applications of this technology, the medical applications of 3D printing are the most talked about and written about.

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Why You Should Choose ULTIFIT Cranial Implants - 3D Incredible

The Cranioplasty is defined as a neurosurgical procedure to sheath an injured portion of the skull; such injuries are caused by accidents, tumors, and congenital defects. It’s quite important that Cranial Implants fit the exact specifications of an individual’s skull in order to attain long-term success and comfort. Thus Cranial Implants are highly intricate and must be manufactured to the highest standards.

To meet these design & functional requirements, 3D Incredible uses patented specifications for ‘UltiFit’ – Customized Cranial Implants. These patient-specific implants help to maintain the required shape and provides better aesthetics. UltiFit Cranial Implants have several benefits over conventional & standard size implants and here we will discuss the top 10 reasons why one should choose UltiFit Cranial Implants for ultimate results.

·         Easy to Use:

UltiFit Cranial Implants are tailored to the anatomy of the specific patient, paving the way for a whole new approach to patient care. Since they are designed with uttermost precision giving exact dimensions and shape as per the patient’s requirement, it becomes relatively easier for doctors to place these implants and conduct the surgery. Along with this, these implants are light in weight and have screw holes for fixing making them very convenient to operate compared to conventional implants.

·         Perfect Fit:

Cranial Implants made from traditional methods typically come with a uniform base, preventing them from sitting flush against the curved surface of the skull. This leaves gaps for fluid and tissue ingress, increasing the risk of microbial infection and tissue inflammation. While UltiFit Cranial Implants are tailored to fit to facilitate surgical implantation and eliminates the gap between the implant and the bone. These implants remain robust and well-integrated with the skull even after a long period of time.

·         Strong and Stable Protection:

3D Incredible uses materials that are strong, resistant to infection and radiolucent. Ti6AI4V ELI alloy is the most commonly used material for making these implants. It is a Titanium alloy having high strength, high corrosion resistance, excellent biocompatibility, good osseointegration, low thermal expansion, and low thermal conductivity. In addition, use of computer-assisted 3D modeling in designing these implants provides perfect shape and size giving it more stability.

·         Complicated surgeries can be Planned Conveniently:

Customized implants allow surgeons to reconstruct the defect in the best possible way along with a reduction in recovery time. Surgeons can study patient’s defect and discuss with 3D Incredible team to design implants as per anatomical requirement, contour, and bone thickness with the help of high tech USFDA & CE approved designing software. 3D Incredible extends support of simulation-based/virtual surgical planning to surgeons; this helps doctors to a great extent during the surgical procedure and reduces the risk of complications.

·         Excellent Aesthetic Look:

3D printed customized implants are anatomically perfect which results in excellent aesthetic look to boosts mental and physical state of the recipients allowing them to return to their normal routine life within very less time.

·         Faster Recovery:

Post-op recovery may get delayed if the surgery performed is not efficient due to longer operative times, multiple implants adjustment, or any infection occurred during the surgery. UltiFit Cranial Implants are perfectly designed implants tailored to the specific requirements of the patient’s condition. Due to the pre-planning of surgery and perfect fitment operating time is less. With these implant, the porosity reaches 95% so that liquids can flow with as little resistance as possible, and the bone tissue is able to penetrate the outer edges of the implant, again as seamlessly as possible, and grow with it. The material used in these implants is also very stable enabling patients to lead a normal life very soon.

·         High Strength to Weight Ratio:

UltiFit Cranial Implants are made from biocompatible Ti6Al4V -ELI (Titanium) which has a very high strength to weight ratio, making them extremely light weighted.

·         Anatomy Models:

The human brain is a complex structure and operating on it can sometimes get difficult for surgeons. Currently, physicians solely rely on MRI or CT scans to study or stimulate surgery, which isn’t completely instructive as they are viewed in 2D on a flat-screen. However, having a tangible model of a patient’s cerebral anatomy will give surgeons a better understanding of each and every part. 3D Incredible makes precise anatomical models which surgeons can use to study and practice before performing complicated surgeries.

·         Reduced Operating Time:

In traditional procedures of implant surgeries, surgeons perform a pre-op assessment on the patient and then visually inspect the placement of the implant. They make repeated adjustments until a ‘best fit’ is found, which takes longer surgery time. While UltiFit cranial implants provide perfect fit where no adjustments are required, thus leading to shorter operating time.

·         Tool Less:

3D printing is a tool-less technology which means less human intervention and faster process, thus 3D printed implants have very less changes of contamination and imperfection.

Conclusion:

Now that you know the criticality of cranial implants; opting for the best quality implants is always better. UltiFit -Customized Cranial Implants by Incredible AM Pvt. Ltd. covers all the aspects and properties to provide the best possible results.

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It’s quite important that Cranial Implants fit the exact specifications of an individual’s skull in order to attain long-term success and comfort. Thus Cranial Implants are highly intricate and must be manufactured to the highest standards.

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The simplest way to understand hybrid manufacturing is as a combination of additive processes 3D printing, known in the context of production as additive manufacturing (AM) and subtractive processes, such as milling.

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Topology Optimizaion for Additive Manufacturing - 3D Incredible

Additive Manufacturing is the potentially disruptive manufacturing technology in which a structural component is a fabricated layer by layer via digital information. Fabricating structural components layer by layer from digital information provides the benefits of increased design freedom, including the ability to exploit the results of topology optimization algorithms to significantly lightweight parts, eliminating system part count by consolidating assemblies into fewer parts, reducing the lifecycle time between concept, design, manufacture, and validated component delivery, a buy-to-fly ratio that approaches unity thereby leading to significant raw material cost savings. AM also has the ability to incorporate added functionality, such as internal cooling channels and thermowells into components; manufacture highly complex geometries that would be impossible or very difficult to be realized with traditional methods.

 Topology optimisation makes the lightweight parts without compromising with the strength. Topology optimisation can help to produce parts with enhanced performance and mechanical properties. It is a technique that optimises the geometry of an object using mathematical calculations. Using topology optimisation software, designers can optimise the material distribution in specific places as the software tool analyses the stresses on the shape and removes any unnecessary material from the design. Which areas of the part are to be optimised is based on several requirements, such as load, deformation, stiffness constraints and boundary conditions. In other words, topology optimisation helps to create the best possible structure of a given part.

Read about – Patient Specific Implant

The benefits of topology optimisation

 Topology optimisation pushes the boundaries of design freedom even further, offering a range of benefits and opportunities for additive manufacturing in the most demanding industries. Additionally, with topology optimisation tools enables the ability to maximise thickness in the areas that need it most, as well as reduce the mass of a part by removing the material in areas that are not exposed to boundary loads. Aerospace is one of the top adopters of topologically optimised designs, thanks to the benefits of creating lightweight parts, reduced support structures and preserved strength of the parts produced. Optimised and additively manufactured components prove to be highly valuable in cutting down costs for launching satellites and space vehicles. A good example is that of aerostructure manufacturer STELIA Aerospace, which has used topology optimisation to produce aeroplane fuselage panels with enhanced stability. There is also an added ecological benefit, with the topology-optimised design leading to less material waste. Since topology optimisation allows additional features such as pore diameter, density, and mechanical properties to be incorporated in specific areas of the engineered component, it is now possible to create functional parts with optimal weight and mechanical properties.

 ·         Discretized domain is provided as the design space materials are defined:- For each element in the design space, the optimizer will attempt to find a density value that minimizes compliance (i.e., maximizes stiffness) while satisfying a simple volume constraint.

·         Interpolation of data fields :- Interpreting the results of density-based topology optimization is where most software applications begin to divert from each other. Interpolation schemes are used to convert the element densities into continuous design variables better suited for optimization algorithms. This results in element densities that can range from 0 (no material) to 1 (solid material) but also vary in between.

·         Geometry Reconstruction :- The geometry reconstruction problem is addressed by implicit modelling technology. With only a few inputs, an implicit geometric representation can be derived straight from a topology optimization result. Manual reconstruction of geometry after topology optimization is generally viewed as a major impediment. The resulting smooth geometry is generated in seconds and can immediately be used in downstream modeling, simulation, and manufacturing functions.

·         Boundary conditions are applied for finite element model :- TA convergence study was not carried out in this work; however, the results are validated through a material test campaign that is the final step of the holistic process flow and is described in subsequent sections of this work.

·         5. Contour slices for manufacturing :- Slicing is an important step for all layer-based additive manufacturing processes. The improved and robust slicing algorithm with efficient contour construction can be used to reduce the slicing time and be able to slice a complex StereoLithography (STL) model with millions of triangle.