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Female mannequin
Cock-up splint
Cock-up splint Image

Technical specifications:

Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated.

Technology highlights:

3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company’s production volume) in a controlled and efficient way.

The translation of a CAD model – which is built from a corrected 3D scan – into a fully digital production process enables Aqtor! to work faster and more efficiently.

Thanks to 3D-printing, products are much lighter and more flexible than traditional products and can be precisely modelled to the patient’s body for a better fit.

Information and use cases:

With 3D-printed projects (Rescue-corset, Cock-up splint and Prosthetic sleeve) Aqtor! Is building the groundwork for the future of modern technical orthopaedics: ‘the digitalization of craftsmanship’.

New 3D techniques are used to achieve faster turnaround times, achieve higher accuracy, produce less waste and optimize the product (e. g. through lightweight structures, minimal material use, integration of additional features such as closures, straps, etc.). Moreover, these 3D-printed designs ensure a better fit and offer a wide spread of pressure points with the advantage of extra comfort when wearing. In addition, these 3D-printed products are customizable in colors and patterns, but also with name and text.

In short, the development of 3D-scanning, modelling, 3D-printing and assembly will change the traditional craft of orthopaedics.

 

Rescue-corset
Rescue-corset Image

Technical specifications:

Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated.

Technology highlights:

3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company’s production volume) in a controlled and efficient way.

The translation of a CAD model – which is built from a corrected 3D scan – into a fully digital production process enables Aqtor! to work faster and more efficiently.

Thanks to 3D-printing, products are much lighter and more flexible than traditional products and can be precisely modelled to the patient’s body for a better fit.

Information and use cases: 

With 3D-printed projects (Rescue-corset, Cock-up splint and Prosthetic sleeve) Aqtor! Is building the groundwork for the future of modern technical orthopaedics: ‘the digitalization of craftsmanship’.

New 3D techniques are used to achieve faster turnaround times, achieve higher accuracy, produce less waste and optimize the product (e. g. through lightweight structures, minimal material use, integration of additional features such as closures, straps, etc.). Moreover, these 3D-printed designs ensure a better fit and offer a wide spread of pressure points with the advantage of extra comfort when wearing. In addition, these 3D-printed products are customizable in colors and patterns, but also with name and text.

In short, the development of 3D-scanning, modelling, 3D-printing and assembly will change the traditional craft of orthopaedics.

Prosthetic sleeve
Prosthetic sleeve Image

Technical specifications:

Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated.

Technology highlights:

3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company’s production volume) in a controlled and efficient way.

The translation of a CAD model – which is built from a corrected 3D scan – into a fully digital production process enables Aqtor! to work faster and more efficiently.

Thanks to 3D-printing, products are much lighter and more flexible than traditional products and can be precisely modelled to the patient’s body for a better fit.

Information and use cases:

With 3D-printed projects (Rescue-corset, Cock-up splint and Prosthetic sleeve) Aqtor! Is building the groundwork for the future of modern technical orthopaedics: ‘the digitalization of craftsmanship’.

New 3D techniques are used to achieve faster turnaround times, achieve higher accuracy, produce less waste and optimize the product (e. g. through lightweight structures, minimal material use, integration of additional features such as closures, straps, etc.). Moreover, these 3D-printed designs ensure a better fit and offer a wide spread of pressure points with the advantage of extra comfort when wearing. In addition, these 3D-printed products are customizable in colors and patterns, but also with name and text.

In short, the development of 3D-scanning, modelling, 3D-printing and assembly will change the traditional craft of orthopaedics.

Cranioplasty implant
Cranioplasty implant Image

Technical specifications:

Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM).

 

Technology highlights:

The PEEK cranioplasty implant serves to protect the patient’s brain when a large bone defect is present. The implant is designed specifically for the patient, based on a CT-scan of his/her skull.

The perfect fit between implant and skull defect reduces the time (and thus cost) in the OR significantly. The patient specific design by engineers allows a perfect esthetic outcome by mirroring the skull curvature of the healthy, unaffected side to the affected side.

 

Information and use cases:

The PEEK cranioplasty is readily available through all of Europe since the very beginning of CADskills.

 

Total temporomandibular joint prosthesis
Total temporomandibular joint prosthesis Image

Technical specifications:
Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM).

Technology highlights:
The total TMJ (temporomandibular- or jaw joint) prosthesis is partly 3D-printed in titanium. This technique was chosen because it allows the integration of a scaffold into the implant that promotes the ingrowth of tissues.
At the inner, bone touching side, the scaffold enables osseointegration (bone ingrowth into the implant), leading to a strong and stable connection, as the bone and implant unite. Higher up, near the condyle, the scaffold allows the attachment and ingrowth of the pterygoid muscle, which would otherwise become useless. This muscle is extremely important to maintain the natural feeling and lateral movement of the lower jaw for the patient. CADskills is the only TMJ prosthesis manufacturer worldwide that incorporates this feature and has patented it.

Information and use cases:
The TMJ prosthesis has recently been launched for clinical use. However, CADskills is already working on a second generation. The goal is to go one step further in patient specific solutions to obtain the holy grail. By designing a prosthesis that is perfectly collaborating with the natural joint on the contralateral side, a longer prosthesis lifetime, full natural mouth opening and full rehabilitation comes in sight.
These technologies are also applied to other fields like to dental rehabilitation (AMSJI) and is being transferred to orthopedics.

Spinal column vertebrae
Spinal column vertebrae Image

Technical specifications:
Printed in DSM Somos® Watershed XC 11122 using Stereolithography (SLA) technology.

Technology highlights:
As one of the industry’s most popular materials, Somos® WaterShed XC 11122 is the obvious solution for numerous applications. Whether you’re a designer looking for highly detailed parts with superior clarity and water resistance, or an engineer focusing on durability for functional testing, Somos® WaterShed XC 11122 mimics the look and feel of clear thermoplastics, such as ABS and PBT.

Information and use cases:
Somos® Watershed XC 11122 was used to create a 3D printed inlet manifold that allowed one of the world’s leading automotive engine manufacturers, Rausch Yates Engines, to test the design durability. In addition, the clarity allowed them to see fuel build-up during testing which enables design changes to be made prior final part production. This has provided Rausch Yates with a competitive edge and shortened their development cycle.

Anatomical heart
Anatomical heart Image

Technical specifications:

Printed using SLS technology in PA2200. SLS-printing is very suitable for producing both small and larger series. As no support structures are required, a large complexity of the components can be obtained.

Information and use cases:

Tenco DDM aims to co-create high-end solutions with customers, by means of 3D-printing or CNC-machining. They offer a perfect fit to ensure a personal and tailormade service and support in additive manufacturing and innovative finishing techniques. The model of the heart can be used in hospitals to evaluate cases before or during surgery, yet many other applications are feasible or conceivable.

Hip implant
Hip implant Image

Technical specifications:

Printed at ESMA with SLM technology in Ti64 on a Renishaw AM250. Heat-treated through Hot Isostatic Pressing (HIP) at Bodycote HIP.

 

Technology highlights:

Where initially cobalt-chromium alloys were selected as bio-compatible materials for medical implants, today these are commonly replaced by the much lighter titanium based alloy Ti64. By designing a scaffold structure on the inside, this hip implant becomes truly lightweight, yet remains as strong as a densely printed or machined part. But the main benefit is of course the possibility to entirely adapt the shape of the implant to the patient. To reduce friction, a ceramic coating has been applied on the ball joint.

 

Information and use cases:

By combining AM technology with CNC turning and milling, ESMA is able to manufacture complete products. ESMA used the Renishaw metal powder bed fusion technology, and is capable of printing in cobalt-chrome and titanium for dental, medical and industrial markets.

Renishaw’s Metal Additive Manufacturing allows parts to be built with few limitations in geometry. Living hinges, interlocking parts, thin wall and hollow objects are possible offering technological benefits, such as patient specific production and the ability to co-print both solid and porous structures promoting ingrowth into the human body. Renishaw is specialised in developing precision equipment to optimise production processes and maximise the output.

Metal and ceramic Additive Manufactured parts often require post-printing heat treatments and specialist thermal processing such as Hot Isostatic Pressing (HIP) to bring the mechanical properties of printed parts to their full potential. In HIP processing parts are subjected to sustained high temperatures and a very high inert gas pressure, resulting in the full removal of porosities. This typically leads to a significant increase of the component’s elasticity and life time.

Temporary Crown & Bridge (teeth)
Temporary Crown & Bridge (teeth) Image

Technical specifications:

Printed with light-curing composite for temporary crown and bridge using SLA technology.

Technology highlights:

In order to serve the demand in the dental market, GC started the development of dental 3D-printable materials. Based on its 97 years of background in dental materials, and specialized in light curing materials, the choice of using SLA (Stereo Lithography Apparatus) as 3D-printing technique was obvious. Nevertheless, the precision of the end product may vary, depending on the geometrical design, device and orientation of the printed part, as well as the material properties itself. Every 3D-printed realization in dental applications, is unique as very person has a different anatomical tooth shape.

Information and use cases:

The first 3D-printing products of GC were shown at the international dental fair IDS 2017, being a model and a temporary bridge with CE certified material. The first clinical application, a 7-unit bridge, was placed in a patient’s mouth in August 2017. It was experienced as a very easy to handle material for both dentist and dental technician, and it was perceived by the patient as very comfortable and aesthetic.

The product will be launched on the European dental market in 2018.

Lower leg
Lower leg Image

Technical specifications:

Laser metal deposition (‘laser cladding’) technology with 316L stainless steel powder.

Technology highlights:

The LCV-Form benefits are design freedom, fast delivery, and high speed 3D-printing: LCV prints a 500 mm high manifold in less than 3 hours. This opens new possibilities for Near Net Shape (NNS) 3D-printing. Applications include gears, cutting tools, punching dies, etc.

Information and use cases:

With 3D-printing by means of laser metal deposition, tracks of molten metal are applied to a base plate or substrate. These metal tracks are deposited in layers by melting a powder (which can be supplied co-axially or laterally) by means of a laser. Stacking these metal tracks on top of each other enables us to create three-dimensional objects. Since multi-axis laser nozzles and substrate clamps are used, there is no need for a powder bed. This opens up new degrees of design flexibility.
This additive shaping technology enables specific structures and even gradient materials to be built up on existing substrates.

Ceramic inteverbral
Ceramic inteverbral Image

Technical specifications:

Silicon carbide intervertebral printed using SLS technology.
 

Technology highlights:

Via Selective Laser Sintering, small silicon and silicon carbide powder particles can be fused together to form a Silicon-Silicon Carbide preform. After post-processing, a near-fully dense ceramic part is obtained. The use of AM for the production of ceramics allows for more design freedom and could open up new possibilities for these materials. Si-SiC for example is light, stiff and has excellent thermal properties, which makes it a suitable candidate for various applications in the aerospace or micro-electronics industry.
 

Information and use cases:

KU Leuven has 30 years of AM experience. Material development in all technical classes is a main focus. Ceramics have historically been challenging to form into complex shapes. By using selective laser sintering, high temperature technical ceramic materials can be produced with a high degree of design freedom. Laser sintered Si-SiC is currently not yet available on the market.

Insole with pressure monitoring
Insole with pressure monitoring Image

Technical specifications:

Printed using Filament Deposition Modeling (FDM): a low-cost technology offering solutions for high-end challenges.

Technology highlights:

Embedded pressure sensors continuously monitor step behavior; it is the integration of “smartness” in the design that turns a relatively simple 3D-printing technique into a true solutions-builder.

Information and use cases:

Many researchers at the VUB are active in the field of prosthesis development. Using electric motors and springs, active prostheses control the movement of knee and ankle, based on a step pattern. The actuation of the prosthesis is based on the feedback of a step monitoring device. The integration of pressure monitoring inside a 3D-printed insole serves as feedback for the step controller, allowing actuating ankle and knee in time. Being less painful than other step monitoring devices and suitable for use in out-of-lab conditions, it is a suitable solution for active prosthesis control.

Fully 3D-printed glasses
Fully 3D-printed glasses Image

Technical specifications:

The eyewear frame was printed in titanium (TiAl6V4) using DMLS – powder bed technology. The lenses were printed in E-Shell 600 biocompatible material.

Technology highlights, information and use cases:

The eyewear frame, produced by Raytech, is completely 3D-printed in titanium which makes it light, durable, rust-proof and anti-allergic. By using metal 3D-printing, unique products can be manufactured tailor-made and fully personalized.

Tenco DDM printed tailor-made lenses. Transparent glasses have been printed using DLP technology in bio-compatible material and both mechanically and chemically polished. Using 3D-printing, fully transparent parts can be generated to evaluate liquid flows, to evaluate optical models and to make end-use parts as the transparent material is UV stable. Patrick Hoet, creator of world’s first metal 3D-printed glasses, provided the design of the spectacles.

Lady’s head and teeth
Lady’s head and teeth Image

Technical specifications:

The female mannequin’s head was printed with SLS technology in polypropylene material on a Ricoh AMS5500P. The teeth were printed with MultiJet technology in VisiJet M2 RWT Plastic Material – Rigid White.

 

Technology highlights:

The Ricoh AM S5500P comes with a maximum building envelope from 550 x 550 x 500 (LxBxH/mm) and distinguishes itself with an open parameter system and the ability to process materials at elevated temperatures (up to 210 C°).
For the Family of the Future project it was decided to print the head in Polypropylene material which has never seen elongation properties that can be established with Additive Manufacturing.

 

Information and use cases:

For more than 80 years, Ricoh has been driving innovation and is a leading provider of document management solutions, IT services, commercial and industrial printing, digital cameras and industrial systems. Today, Ricoh is drawing on its heritage and expertise to become a leading innovator is the disruptive arena of Additive Manufacturing.
The AM S5500P machine is available in Europe since November 2015 and immediately found its way to leading Automotive companies such as Daimler and Volkswagen.
RICOH commits to further develop more unique materials for Powder Bed Fusion (Laser Sintering) technology as well as new hardware innovations.

Female mannequin
Cock-up splint Image
Cock-up splint
Technical specifications: Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated. Technology highlights: 3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company?... Lees meer
Rescue-corset Image
Rescue-corset
Technical specifications: Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated. Technology highlights: 3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company?... Lees meer
Prosthetic sleeve Image
Prosthetic sleeve
Technical specifications: Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated. Technology highlights: 3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company?... Lees meer
Cranioplasty implant Image
Cranioplasty implant
Technical specifications: Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM).   Technology highlights: The PEEK cranioplasty implant serves to protect the patient’s brain ... Lees meer
Total temporomandibular joint prosthesis Image
Total temporomandibular joint prosthesis
Technical specifications: Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM). Technology highlights: The total TMJ (temporomandibular- or jaw joint) prosthes... Lees meer
Spinal column vertebrae Image
Spinal column vertebrae
Technical specifications: Printed in DSM Somos® Watershed XC 11122 using Stereolithography (SLA) technology. Technology highlights: As one of the industry’s most popular materials, ... Lees meer
Anatomical heart Image
Anatomical heart
Technical specifications: Printed using SLS technology in PA2200. SLS-printing is very suitable for producing both small and larger series. As no support structures are required, a large complexity of the components can be obtai... Lees meer
Hip implant Image
Hip implant
Technical specifications: Printed at ESMA with SLM technology in Ti64 on a Renishaw AM250. Heat-treated through Hot Isostatic Pressing (HIP) at Bodycote HIP.   Technology highlights: Where initially c... Lees meer
Temporary Crown & Bridge (teeth) Image
Temporary Crown & Bridge (teeth)
Technical specifications: Printed with light-curing composite for temporary crown and bridge using SLA technology. Technology highlights: In order to serve the demand in the dental market, GC sta... Lees meer
Lower leg Image
Lower leg
Technical specifications: Laser metal deposition (‘laser cladding’) technology with 316L stainless steel powder. Technology highlights: The LCV-Form benefits are design freedom, fast delivery, and high speed ... Lees meer
Ceramic inteverbral Image
Ceramic inteverbral
Technical specifications: Silicon carbide intervertebral printed using SLS technology.   Technology highlights: Via Selective Laser Sintering, small silicon and silicon carbide powder particles can be ... Lees meer
Insole with pressure monitoring Image
Insole with pressure monitoring
Technical specifications: Printed using Filament Deposition Modeling (FDM): a low-cost technology offering solutions for high-end challenges. Technology highlights: Embedded pressure sensors continuously monitor ... Lees meer
Fully 3D-printed glasses Image
Fully 3D-printed glasses
Technical specifications: The eyewear frame was printed in titanium (TiAl6V4) using DMLS – powder bed technology. The lenses were printed in E-Shell 600 biocompatible material. Technology highlights, information and us... Lees meer
Lady’s head and teeth Image
Lady’s head and teeth
Technical specifications: The female mannequin’s head was printed with SLS technology in polypropylene material on a Ricoh AMS5500P. The teeth were printed with MultiJet technology in VisiJet M2 RWT Plastic Material – Rigid ... Lees meer