Production of Custom Implants Using Metal Powder Bed Fusion

Additive manufacturing is gaining increasing importance in the medical field, particularly metal 3D printing, which opens up new possibilities for patient-specific implants. Using Metal Powder Bed Fusion (MPBF), highly precise and individually tailored medical components can be produced, which would be difficult to achieve with conventional manufacturing methods. A current example is the production of shoulder arthrodesis plates, which are used for surgical shoulder stabilization after severe injuries or medical conditions.

In traditional manufacturing, such implants require significant design and production effort. Their complex geometry often necessitates a combination of milling, bending, and manual post-processing, leading to longer production times and reduced reproducibility. To address these challenges, Metal Powder Bed Fusion (MPBF) was chosen as the manufacturing technology. The use of the Eplus3D EP-M260 printer enabled rapid prototype development while reducing costs for implant production.

The selected material was a medically certified titanium alloy (VT6), known for its high biocompatibility and mechanical strength. The printing process took approximately 12 hours, with a layer thickness of 30 micrometers. After printing, a heat treatment at 700 degrees Celsius was performed to relieve residual stress, followed by removal of support structures and final surface treatment using sandblasting. For precise threads, the corresponding holes were left out in the 3D model and later machined via CNC processing to ensure dimensional accuracy and surface quality.

The EP-M260 printer is characterized by high material density, a dual-laser system, and an optimized layer application strategy, achieving high printing speed and process stability. With a build volume of 260 × 260 × 390 mm, the system is suitable for medium-sized implants with complex geometries. In addition to titanium, other biocompatible materials such as stainless steel or cobalt-chrome can also be processed, further expanding its applications in the medical field.

Manufacturing patient-specific implants using MPBF offers numerous advantages. Besides improved anatomical adaptation and high mechanical durability, the method enables resource-efficient production with minimal material waste. Additionally, optimized designs can be utilized to create functional properties such as porosity or lattice structures, which promote tissue integration.

The successful production of shoulder arthrodesis plates demonstrates the potential of metal 3D printing in medical technology. Future developments in additive manufacturing are expected to bring additional biocompatible materials and optimized processes, making the customization of implants even more efficient. As technology advances, individualized medical solutions could increasingly become the standard, contributing to sustainable improvements in patient care.