Biometals and the World of 3D Printed Prostheses

Over the last couple of years, innovations in prosthetics have expanded significantly. Although we are still far from the age of true cyborgs, thanks to the advancements in 3D scanning and additive manufacturing, the field of medical implants has become highly customized, considering each patient’s unique anatomy, with increasingly precise results.

As the field of neuro-prosthetics (brain-controlled artificial devices) improves quickly, experts are now able to offer a much-improved quality of life. A key enabler of this progress is 3D printing, particularly through the advanced technology of DMLS (Direct Metal Laser Sintering).

In this article, we focus on the type of biometals used in 3D printed implants (built-in medical devices) and how additive manufacturing can improve people’s lives immensely, while transforming the future of prosthetics.

What exactly is a prosthesis?  

In simple terms – and without diving deep into medical phrases - prosthetics refers to the industry and science of artificial limbs and body parts. The term "prosthetic" can also be used as an adjective, as in "prosthetic limbs."

A prosthesis or implant typically refers to an artificial device integrated into the body. Such devices can range from hip and knee implants to cranial implants designed for post-trauma skull reconstruction, to 3D printed titanium screws. Thanks to metal 3D printing technologies, such as DMLS, the possibilities in personalized healthcare are rapidly growing.

Titanium Cranial plates / Source: eplus3D.com

Additive manufacturing can largely support traditional methods in this medical field. The specialty of the metals used by the DMLS technology is that they have excellent mechanical properties.

What are biometals?

In the field of medical technology, implants and prostheses are made of titanium, stainless steel, or cobalt-chromium alloys. Recently, researchers have begun developing magnesium alloys for use in temporary implants.

These high-standard metals offer several key benefits:

·   Corrosion resistance: prevents the release of harmful metal ions, which could cause systemic toxicity in the patient’s body

·   Biocompatibility: ensures the integration with human tissue

·   Strength and durability: essential for long-term usage

These features are crucial when using them as a built-in artificial device. To get the best implant performance and the longest lifespan of one device, it’s inevitable to choose the right biometal.

Nano-textured titanium supports the process of osseointegration, which is an essential step in the post-surgery process for patients. It means the structural and functional bond between the living bone and the implant. The 3D printed titanium part’s nano-scale surface triggers the bone-forming cell activity, so it helps to get better results in bone integration.

Cobalt-chromium is commonly used for joint replacements, like knee and hip implants. This metal can be combined with a titanium coating to increase its benefits, like enhanced osseointegration. Cobalt-chromium offers exceptional wear resistance and mechanical strength, which makes it perfect for orthopaedic implants.

When a temporary implant is needed, stainless steel offers a cost-effective and still highly durable option. While it's more affordable, its strength still makes it possible to use for medical devices. They often use 3D-printed surgical instruments made of stainless steel, too.

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Benefits of DMLS for Medical Devices

DMLS (Direct Metal Laser Sintering) uses a high-powered laser to selectively fuse the metal powder layer by layer. The ultra-fine metal powder is spread across the building platform.

Just like the SLS (Selective Laser Sintering) technology that uses PA as its material, this technology enables us to create objects with complex geometries and high precision.

It offers unmatched design freedom, so the question is not manufacturability anymore, but functionality.

This 3D printing technology is incomparably material efficient and precision-driven to print the most accurate parts with fine details.

DMLS (Direct Metal Laser Sintering) is revolutionizing orthopaedic implants, especially the hip, knee, and spinal prostheses. However, continued research into post-processing and regulatory approval is crucial to ensure the highest levels of safety and performance.

Future trends in biometal prostheses

While metal 3D printing in healthcare has been around for over a decade, it remains a cutting-edge technology, as broader clinical adoption is still in progress.

The first major milestone was in 1995, when researchers demonstrated a system for milling titanium cranial implant plates. Since then, scientists and manufacturers have been actively working on improving the efficacy, safety, and precision of additive-manufactured medical devices.

One exciting direction that could make a difference in the healthcare industry involves smart implants. These built-in smart devices are capable of monitoring the patient’s healing process in real-time. Its sensors could provide feedback to doctors, helping the post-surgery care more effectively.

Source: codetechnology

Bioabsorbable alloys are another ground-breaking development. These implants were designed to degrade safely within the body over time. These innovative 3D printed implants use magnesium and zinc to eventually absorb without causing any harm to the patient. The advantage of metals that can dissolve as the body heals is the fact that it eliminates the need for a second surgery.

Looking ahead, these innovations - and many more upcoming developments - have the potential to transform the medical device industry, while benefiting from the advanced solutions of additive manufacturing.

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