Inside3DPrinting_DaveFlynn

Engineering on Human Anatomy

Presented by David Flynn

Materialise USA

Committed to innovations for a

better and healthier world

Inside 3D PrintingSan Jose, CA

09/18/13

About Materialise

• Company

• Established 1990

• Leuven, Belgium

• ±1000 employees

• Worldwide presence

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We are Materialise

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Additive Manufacturing Services

Industrial Prototyping & Mfg Services

Software for Additive Manufacturing

• Magics

• Streamics

• 3-Matic

Biomedical Engineering

Mimics Innovation Suite

Cranio-MaxilloFacial

Clinical Service

RapidFit+

Custom modular fixture development service

i.Materialise

Online 3D Printing Services

.MGX

Additive Manufactured Artwork

Orthopaedics

Clinical Service

PRODUC-

TION

PRODUC-

TION

SOFTWARESOFTWARE

SERVICESSERVICES

Diversity means strength

Courtesy of TotalSim Ltd.

Courtesy of IDEE / Maastricht Instrument

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Mimics Innovation Suite:Our Total Solution

• Mimics®

• Processing software to take 2D image (CT, MRI, etc.) toconstruct 3D models

• 3-matic®

• Design and meshing software ideal for anatomical data

• Services

• Anotomical Models, HeartPrint

• Engineering services5

Medical scanner (CT/MR/US)

Your own PC or laptop

Mimics

3-matic ®

• Design and meshing software ideally suited for use with anatomical data

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Design: custom cranial plate Meshing: vertebrae remeshing

Case Studies

•Visual and Diagnostic Aids:

• Medical Models

• Surgical Intervention

•Engineering Functionality:

• Surgical Guides

• Patient Specific Implants

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MEDICAL MODELS AS

VISUALIZATION AND

DIAGNOSTIC AIDS

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Medical Models

• Separate conjoined twins

• Arteries could not be tracked with X-rays

• Operation time reduced from 97 to 22 hours

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Kenneth E. Salyer, M.D. and Objet Geometries Ltd., 2002

Medical Models

• 3D ultrasound with tomographic output

11Jorge Santos et al. 2009, Royal College of Art, UK

MEDICAL MODELS USED FOR

SURGICAL INTERVENTION

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SURGICAL INTERVENTION CASE

STUDY: AORTIC DISSECTION

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Case Study: Aortic Dissection

• Demographics• Incidence 1-10:100,000

• Rarely < 60

• Mostly male

• Medical emergency• Tear in inner wall of aorta

• Blood flows between layers

• True vs false lumen

• 80% mortality rate if rupture

occurs

Modeling from CT images

Outcomes

• No intervention possible

• Model revealed multiple leakage paths in need of repair

• Location of leakage paths closer to neck arteries than originally thought

• Comorbidity risks too high

• Gave tangible view on leakage paths and relation to connecting anatomy

• Modeling software and 3D printed model helped identify new risks

SURGICAL INTERVENTION CASE

STUDY: CONGENITAL CARDIAC

MALFORMATION

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Case: Congenital Cardiac Malformation

• Irregular Anatomy

• No two cases are the same

• Provides guidance for the surgeon

• Benefits

• Anatomically accurate

• Capture arrangement of chambers and GV

• Model characteristics

• Flexible to mimic soft tissue

• Ability to bend and cut

Emory University Hospital

How was it created?

Emory University Hospital

SURGICAL GUIDES: TOTAL

KNEE REPLACEMENT

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Patient Specific Guides for Total Knee Replacement

Scan

Patient

Construct 3D models

Plan the surgery

Design & build guides

Enter the OR

Scan

Patient

Construct 3D models

Plan the surgery

Design & build guides

Enter the OR

Patient Specific Guides for Total Knee Replacement

Scan

Patient

Construct 3D models

Plan the surgery

Design & build guides

Enter the OR

Patient Specific Guides for Total Knee Replacement

Scan

Patient

Construct 3D models

Plan the surgery

Design & build guides

Enter the OR

Laser Sintering (LS)

Patient Specific Guides for Total Knee Replacement

Scan

Patient

Construct 3D models

Plan the surgery

Design & build guides

Enter the OR

Patient Specific Guides for Total Knee Replacement

SURGICAL GUIDES: CMF

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CMF Software & Surgical Guides

Upload CT data

Perform Planning session online with

Materialise

Printing of planning outcome: Models

and/or guides

Synthes to deliver models, guides and /

or implants

Case presented by Daniel Buchbinder, MD DMD, Beth Israel New York

CMF Software & Surgical Guides

Guide Benefits

• Increase collaboration between doctors

• Reduced cost and complexity of procedure

• Decrease the number of surgical instruments to sterilize

• Potential to decrease OR time

• Expedite patient recovery

• Increase longevity of implants

• Allow surgeon to try different approaches before lifting a scalpel

• Avoid making critical decisions on the spot

Guide Production

• 5 dedicated LS machines in Belgium

• Started USA Production 2010

• Key partners in USA

• Surgeons predominently in USA

• 3 LS Machines � 6 by end of 2011 in Plymouth, MI

• Room to grow to 24 machines!

• Medical Production Focus in USA (growth)

PATIENT SPECIFIC

IMPLANTS

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• Design in 30 minutes

• Design was watertight and ready to print

• Model printed in Ti6Al4V with EBM (Arcam)

Custom Implant Design- 3-matic®

Custom Implant Design

• Cranio-Plate

• Porosity Built In

Patient specific implant design

• Increasing demand for revision total hip arthroplasty

• Growing number primary implants

• 15% require revision

• >50% involve acetabular component

• Extensive bone loss

• Complex defects

• Patient-specific surgical planning

• Custom implant design

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Mechanical loosening

Hip instability

Infection

Fracture

Patient-Specific Acetabular Cup Implant

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Segmentation/reconstruction

of anatomy Custom fit implant designed Automated screw placement

based on bone thickness

Mesh refinement of bone and

implant assembly

Court

esy

of B

art

els

et al. K

U L

euven

CT-derived material properties Patient-specific MSM

Patient specific implant design using FEA

• Model results

• Manufacturing (selective laser melting)

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Implant integrity Bone loading

Custom Implants– Acetabular Cup

• Custom Acetabulum Implant

Where do we go from here?

• Future of healthcare is customization

• Key to better patent care lies in patient specific solutions tailored to individual anatomy

Thank you!

dave.flynn@materialise.com