A technical article by Niko Mroncz, Sales Engineer Xometry Europe
3D printing established itself early on in medicine and healthcare. Today, personalized parts, medicines or administration aids based on individual data improve the treatment of patients. These printed aids promote recovery and reduce complications, increasing the chances of successful therapies. In principle, 3D parts are more compatible with the human body than conventionally manufactured products. For example, they are easier to adapt to the patient’s individual anatomy and needs. Interested users of new and further developments will find some practical tips below.
Our Xometry platform places production orders from the healthcare sector on a daily basis. In addition to medicine, additive methods affect related services such as pharmacies, therapists or developers and manufacturers of medical devices. The economic benefits of 3D printing also play a role for these users. For example, the manufacture of medical products using on-demand production makes stock levels superfluous. Patients also no longer have to wait so long for aids, and adjustments to the design can be made quickly after an initial test. Compared to conventional manufacturing processes, 3D printing is also more environmentally friendly and reduces material waste.
Printing a complex medical model in the laboratory. Picture: Xometry
3D printing in the healthcare sector
Traditionally, the production of medical aids involves a great deal of manual labor. Raw materials are shaped by grinding, carving and machining until the end product is as individual as possible. Additive methods make the process simpler, less labor-intensive and therefore usually faster and cheaper. Designs for such 3D products are usually created using computer-aided design software (CAD). However, it is also possible to produce models using 3D scans created in digital resonance tomography (MRT). Many users use a production platform such as Xometry to implement their ideas. This platform finds the right manufacturer for the desired product from a huge network of companies. Some medical facilities also have their own printers, which they use to produce directly on site.
Applications
The success of 3D printing in the medical and healthcare sector is based on the fact that it can be used to create individual and patient-specific designs. The possibilities of additive production are almost unlimited. It is therefore used for specialized and patient-specific surgical tools, procedure guides and even facial reconstruction. Based on feedback from surgeons, quick and precise design adjustments can be made to such products.
Implants
3D-printed implants can be produced using many different printing processes and from a variety of materials. Among other things, spinal and orthopaedic implants, prostheses, sockets and parts, dental crowns, bridges and other orthodontic tools are now being printed. Delivery devices such as inhalers, plasters and implants, hearing aids and detailed anatomical models are also produced to meet the personal needs of patients. Such personalized parts can shorten surgery times and avoid complications that would arise from manually modifying standard-sized implants.
Prosthetics
Printed prostheses are one of the most impressive solutions that 3D printing opens up to the healthcare sector. For amputees, personalization has created new freedoms: Additively created parts adapt perfectly to the patient’s body and offer greater comfort and functionality. Conventional prostheses and their components are expensive and require regular, time-consuming manual adjustments. A 3D-printed prosthesis, on the other hand, is often more cost-effective. They can also be delivered quickly and require less adjustment as they are made to measure. This makes life easier, especially for children, as they quickly grow out of their prostheses.
Anatomical replicas
In addition to prosthetics, anatomical replicas can be produced for education, training and planning operations. Such 3D impressions resemble real organs exactly, as they are created on the basis of actual image data of the patient. This allows doctors to practice major operations in advance. Complicated procedures are simulated on the models so that medical staff can practice realistically. This also results in fewer complications and a higher chance of successful interventions. At Xometry, for example, we teach full-color printing using PolyJet 3D printing technology to create lifelike replicas with realistic textures and colors.
Printing organs and tissue
Bioprinting is used to produce scaffolds that resemble human tissue. This is a first step in the production of printed organs and tissues. Such machine-produced organs have the potential to save millions of lives. Sick people would no longer have to wait on long waiting lists for a donor organ. Research into this is being carried out intensively, but it is still a dream of the future.
Further applications
Medical devices and tools that are specifically tailored to a patient are already being printed. The method is also used for individual drug dosages and formulations. This reduces the risk of side effects. For example, the US Food and Drug Administration (FDA) approved the epilepsy drug Spritam, which is produced using the 3D printing process. The technology enables the tablets to have a porous surface and the improved preparation is easier to dissolve than other pills.
Customized hand splint made of plastic, produced in a 3D printer. Picture: Xometry
Disadvantages of 3D printing in the healthcare sector
Despite all the undeniable advantages, there are also weaknesses. For example, the choice of materials suitable for 3D printing in the medical sector is still more limited than with traditional manufacturing methods. There are also some problems in achieving a consistent quality of the printed parts.
The right 3D technologies
To date, different technologies have been used in the healthcare sector – each has its advantages and disadvantages. Below we present the 3D technologies most commonly used in the healthcare industry.
Stereolithography (SLA)
Printers cure liquid resin with lasers. At Xometry, we teach the process for manufacturing high-resolution and precise products with smooth surfaces. It is useful for the production of prototypes and anatomical models, but requires a certain amount of post-processing.
Selective laser sintering (SLS)
This technology is preferred for complicated mechanical and customer-specific parts. High-power lasers fuse powdered material into an end product. Nylon and other polyamides (PA) are frequently used. SLS nylon prints can be sterilized as the material is very heat-resistant. The large and complex printers are mainly used in industry. However, the technology can also be used by smaller users via a production platform because they do not need their own printer.
Fused Deposition Modeling (FDM)
An FDM printer melts a thermoplastic filament and strategically extrudes it onto a build platform. It builds layer by layer until the final product is completed. This process is cost-effective and is ideal for simple prototypes and parts. However, the lower resolution means that it is not the first choice for complex products and is likely to require post-processing.
Direct Metal Laser Sintering (DMLS)/Selective Laser Melting (SLM)
Both types of printers have lasers that melt metal powder to produce strong and biocompatible parts, such as customized implants. They are very expensive to purchase and operate and are therefore almost exclusively intended for industrial environments.
Suitable printing materials
There are various materials for 3D printing in the healthcare sector, all of which must meet strict safety, quality and efficiency standards. They must be stable, durable, sterilizable, corrosion-resistant and lightweight. Not all 3D printer-compatible materials are safe for medical use. Below is a list of the most commonly used 3D printing materials in medicine and healthcare that can meet the necessary requirements:
– Nylon PA-12
– PC-ISO
– ABS M30i
– Titanium
– Cobalt chrome
– Stainless steel
– Thermoplastic polyurethane (TPU)
– Polylactic acid (PLA)
– Polyetheretherketone (PEEK)
– Polyetherketoneketone (PEKK)
– Polymethyl methacrylate (PMMA)
– Bio-ceramics
– Polyethylene glycol (PEG)
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