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The use of additive manufacturing in the custom design of orthopedic implants
Mid Sweden University, Faculty of Science, Technology and Media, Department of Engineering and Sustainable Development. (Maskin)
2011 (English)Licentiate thesis, comprehensive summary (Other academic)
Place, publisher, year, edition, pages
Sundsvall: Mid Sweden University , 2011. , 14 p.
Series
Mid Sweden University licentiate thesis, ISSN 1652-8948 ; 63
Keyword [en]
additive manufacturing (AM), electron beam melting (EBM), total hip replacement (THR), orthopedic imiplants, digital design, computer aided design (CAD), bone plates
Identifiers
URN: urn:nbn:se:miun:diva-14390ISBN: 978-91-86694-42-5 (print)OAI: oai:DiVA.org:miun-14390DiVA: diva2:436633
Presentation
2011-05-27, 10:00 (Swedish)
Opponent
Supervisors
Available from: 2011-08-24 Created: 2011-08-24 Last updated: 2012-08-01Bibliographically approved
List of papers
1. Application of electron beam melting to titanium hip stem Implants
Open this publication in new window or tab >>Application of electron beam melting to titanium hip stem Implants
2008 (English)In: / [ed] Katalinic, B., Vienna: DAAAM International Vienna , 2008, 1559-1560 p.Conference paper, Published paper (Refereed)
Abstract [en]

The Free Form Fabrication Process (FFF) is nowadays an accepted technology widely used for prototyping and manufacturing. However, it is still in an expansive phase and new applications like direct manufacturing of implants are evolving continuously. Present work describes the possibilities provided by the electron beam melting (EBM) method for orthopedics; in particular hip stem implant manufacturing. The conventional machining used for individually adapted prostheses typically involves advanced milling with the drawback of removing up to 80% of the material. This paper addresses the economic feasibility of using an additive approach for the manufacturing of typical orthopedic implants. The studied implants were manufactured from biocompatible Ti-6Al-4V alloy using both EBM and conventional CNC technologies and compared according to material consumption, manufacturing time and cost.

Place, publisher, year, edition, pages
Vienna: DAAAM International Vienna, 2008
Keyword
orthopedic implants, hip stem, electron beam melting, free form fabrication, economic feasibility
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:miun:diva-7833 (URN)978-3-901509-68-1 (ISBN)
Conference
International Conference on Additive Technologies
Projects
Sportstech1
Available from: 2008-12-19 Created: 2008-12-19 Last updated: 2011-08-24Bibliographically approved
2. Production of Customized Hip Stem Prostheses: a Comparison Between Machining and Additive Manufacturing
Open this publication in new window or tab >>Production of Customized Hip Stem Prostheses: a Comparison Between Machining and Additive Manufacturing
2013 (English)In: Rapid prototyping journal, ISSN 1355-2546, E-ISSN 1758-7670, Vol. 19, no 5, 365-372 p.Article in journal (Refereed) Published
Abstract [en]

Purpose - The purpose of this paper is to study the use of the additive manufacturing (AM) method, electron beam melting (EBM), for manufacturing of customized hip stems. The aim is to investigate EBM's feasibility and commercial potential in comparison with conventional machining, and to map out advantages and drawbacks of using EBM in this application. One part of the study concerns the influence on the fatigue properties of the material, when using the raw surface directly from the EBM machine, in parts of the implant.Design/methodology/approach - The research is based on a case study of manufacturing a batch of seven individually adapted hip stems. The stems were manufactured both with conventional machining and with EBM technology and the methods were compared according to the costs of materials, time for file preparation and manufacturing. In order to enhance bone ingrowths in the medial part of the stem, the raw surface from EBM manufacturing is used in that area and initial fatigue studies were performed, to get indications on how this surface influences the fatigue properties.Findings - The cost reduction due to using EBM in this study was 35 per cent. Fatigue tests comparing milled test bars with raw surfaced bars indicate a reduction of the fatigue limit by using the coarse surface.Originality/value - The paper presents a detailed comparison of EBM and conventional machining, not seen in earlier research. The fatigue tests of raw EBM-surfaces are interesting since the raw surface has shown to enhance bone ingrowths and therefore is suitable to use in some medical applications.

Keyword
Orthopedic implants, hip stem, electron beam melting, additive layer manufacturing
National Category
Medical Materials
Identifiers
urn:nbn:se:miun:diva-14391 (URN)10.1108/RPJ-07-2011-0067 (DOI)000323021700008 ()2-s2.0-84881395614 (Scopus ID)
Available from: 2011-08-24 Created: 2011-08-24 Last updated: 2016-09-21Bibliographically approved
3. Implementation of digital design and solid free-form fabrication for customization of implants in trauma orthopaedics
Open this publication in new window or tab >>Implementation of digital design and solid free-form fabrication for customization of implants in trauma orthopaedics
2012 (English)In: Journal of medical and biological engineering, ISSN 1609-0985, Vol. 32, no 2, 91-96 p.Article in journal (Refereed) Published
Abstract [en]

Bone plates for the fixation of complex fractures in proximity to joints often have to be reshaped to follow the bone contour. Good adhesion of the screws in areas where the bone is osteoporotic is also a challenge. One possible solution to these issues is to tailor-make plates by creating a digital three-dimensional model of the fracture from a computed tomography (CT) scan, digitally reducing the fracture, designing a plate, and finally manufacturing it directly from the digital model with solid free-form fabrication (SFF) technology. This study designs a custom plate for a distal tibia fracture, and investigates and refines the procedure from the CT scan to the final implant, with the aim of making it usable in trauma orthopaedics. The bone plate is manufactured using electron beam melting (EBM) technology. The challenges of bone plate design using digitalization and SFF are discussed. The virtual models created by the engineer while digitally reducing the fracture and modeling the plate are valuable for the physician while planning the surgery. A combination of surgery planning and digital plate design improves the surgeon's preparations and ensures correspondence between the plan and the designed implant. The proposed procedure, with the approximate required time in brackets, includes the separation of bone in the DICOM file (60 min), the reduction of fracture (5-30 min), revision (30 min), modelling of the plate (30-120 min), confirmation (30 min), manufacturing with SFF (10 h), post-processing (60 min), and finally cleaning and sterilization (90 min). The whole procedure requires about three working days.

Keyword
Bone plate; Electron beam melting; Orthopaedic implant; Solid free-form fabrication; Trauma
National Category
Biomedical Laboratory Science/Technology
Identifiers
urn:nbn:se:miun:diva-14393 (URN)10.5405/jmbe.883 (DOI)000303147300003 ()2-s2.0-84864007060 (Scopus ID)
Available from: 2011-08-24 Created: 2011-08-24 Last updated: 2014-09-15Bibliographically approved

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