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30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
29th March 2007
Innovations in Materials and Manufacturing of Denta l Devices
Dr Martin Kearns Sandvik Osprey Ltd., Red Jacket Works, Milland Road, Neath, SA11 1NJ
www.smt.sandvik.com/osprey
Alloy Metal Powders for Dental Applications
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Introduction
� Sandvik Materials Technology & Sandvik Osprey
� Sandvik Bioline
� Range of products
� Powder Metallurgy
� Technologies: MIM, SLM, Coating, HIP
� Powder production
� Benefits of net shape manufacturing
� Case Studies
� Dental & Medical components
� Current trends
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
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� High quality wrought alloys in bar, wire,
strip, profiles and tubular products.
� Bio-compatible, with excellent corrosion
resistance and exceptional strength suitable
for medical implants, fracture management
systems, surgical and dental tools and instruments
� Wide variety of alloys (Stainless steels, Titanium and Cobalt alloys) and product forms supported by advanced R & D facilitie s
� Special net shape powder products from Sandvik Ospre y
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Sandvik Bioline stainless and special alloys are well suited for various dental applications such as -
Dental burrs & drillsFiles & reamersBroachesInter-dental brushesScale/tartar removersFixture driversDental implants
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Trends in Metal Prices Feb 2006-March 2007Ni, $/MT
10000
50000
Mo, $/kg
85
50
Co, $/lbCr, $/MT
7000
5800 12
32
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Conventional Cast / Wrought / Machine
Melting
Cast
Forge
Roll/Extrude/Draw
Machine
Pickle/Re-machine/grind
Finished shape
Heat treatment
Scrap.. Ends, runners, risers
Scrap.. Forging flash
Scrap.. Edge trim, pipe defects
Scrap.. Swarf, turnings, chips
‘Fly-to-buy’ ratio for some Products (e.g. Ti alloys)can be <10%
Scrap.. Grindings, sludge
Hard materialsdifficult to machine
Expensive thermo-mechanicalforming/ inter-anneals
Slow-cool, segregation
Distortion
Surface damageembrittlement
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Powder Metallurgy Routes
Melting
Atomise
Sieving/sizing
Die Pressing
Finished shape
Heat treatment
‘Scrap’.. Melting losses
Scrap.. Oversize remelted
High materials utilisation throughout
Laser deposition MIM Net shape HIP
Machine off orpickle canister
Recyclespruesrunners
Recycleoverspray
Finish grindor coining
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Powder Metallurgy Forming Routes: size & number of parts
PartWeight
grammes
Number of Parts
10 102 103 104 105 106
1
1
10
102
103
104
105
106
107
0.1
RapidPrototypes
1 tonne
1 kg
MIM
HIPpedParts
Uniaxial Pressings
MIM
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
� 5 powder production lines
� High volume production lots - 3000Kg
� Experimental lots – 20kg
� Nitrogen & Argon atomising
� Powder sizing by ultrasonic sieving
and air classification.
� International & customised alloy
specifications
� Standard & tailored powder size ranges
� Size & chemical analysis in-house
The Powders Group
Sandvik Osprey / BASF Meeting – 30 October 2006
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
SEM Images of MIM Powders
� Gas atomised alloy powders
� Spherical shape
� Low oxide / impurity levels
� Good flow & mixing characteristics
� Refined, homogeneous microstructures
� Isotropic properties approaching
those of wrought products
� Available in a wide range
of alloys and size ranges
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Particle Size Rangesfor different fabrication methods
Filters & Foams
Electron Beam Melting
Press & Sinter typical
Hot Isostatic Press
Selective Laser Melting
Cold Spray
MIM
Coatings
MicroMIM
Fabrication Method 50 100 1500 Size Microns
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
MIM - Particle Size Distributions
� - 38 micron (Sieved)
� - 32 micron (Sieved)
D10 3.5 – 5.0 microns (ave. 4.3 microns)
D50 10.0 – 13.0 microns (ave. 12.0 microns)
D90 27.0 – 31.0 microns (ave. 30.0 microns)
� 80% -22 microns (Air Classified & Sieved)
D10 3.0 – 4.5 microns (ave. 4.1 microns)
D50 9.0 – 12.0 microns (ave. 11.3 microns)
D90 25.0 – 29.0 microns (ave. 26.0 microns)
� 90% -22 microns (Air Classified & Sieved)
D10 3.0 – 4.0 microns (ave. 3.7 microns)
D50 8.0 – 11.0 microns (ave. 10.5 microns)
D90 19.0 – 22.0 microns (ave. 21.5 microns)
� Finer Grades; 90% -16 microns & 90% -10 microns
� Micro – MIM 80% -5 microns
Increasingprecision
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Process
Sintering
Metal Metal powder BinderBinder
Mixing/ Kneading
Injection Molding
De-binding
Secondary Operations
Metal Injection Process Steps
Batch sinterfurnace
InjectionMouldingMachine
High shearMixer
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
� Stages in MIM processing
Feedstock(powder+ binder mix)
‘Brown part’after solventdebindering
Injection-moulded‘Green part’
Finished densesintered part
Metal Injection Moulding Process Steps
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Relative cost vs shape complexity
Low Medium High
Unitcost
Shape Complexity
Machining
MIM
Press &Sinter
Casting
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
MIM Proposition
Cold ForgingEliminate secondary
processingMIM
Coverage
Die CastingMaterials Flexibility
Investment CastingDimensional Precision
MachiningComplex shapesDifficult materials
Powder MetallurgyBetter strengthNo finishing
• MIM offers a rangeof advantages overother manufacturingmethods.
• Ideal for high volumeManufacture of smallIntricate components.
• Combination of highPrecision, goodmechanical propertiesand flexibility in materials.
• Short development time- 10 weeks from design to manufacture
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
MIM Capabilities & Tolerances
Investment Cast MIM
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
MIM impact on orthodontics� Orthodontics is a $700million industry worldwide (e st. $130M in
MIM parts)
� The brackets used are small and extremely complex i n shape
� Drive to make even smaller, less visible with thinn er walls & blind pockets.
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
MIM for Orthodontic Brackets
� ‘Old’ Investment Casting technology� Injection mould pattern for each individual bracket in polymer, assemble in to “trees” and
investment cast
• 7 process steps
• production time = 30 days
• Scrap rate = 90%
� MIM technology� Injection mould, de-bind and sinter
• 3 process steps
• Production time = 2 days
• Scrap rate < 5% (sprues and runners are recycled in-house)
• No need for secondary machining & deburring.
• 0.1g per part: metal powder cost ~0.2p; manufacturing cost 30p; selling price through distributor ~50-100p; selling price to dentist 150-500p
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Practical benefits of MIM
� Benefits -
� Faster processing time
� Smaller inventories
� Reduced lead times
� Overhead reduction
� Difficult geometry made easy
� Higher quality at lower cost
� Virtual elimination of scrap and hence highly energ y efficient
� Sandvik Osprey has, in conjunction with its custome rs, developedpowders in many different alloys for this sector.
� This includes low nickel variants for patients who display nickel sensitivity.
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Dental/Medical Sector by Alloy Type
� F75: most common alloy for implants/orthodontic bra ckets (CoCrMo)
� 17-4PH precipitation hardening stainless steel for orthodontics &
medical instruments (FeCrNiCuNb).
� Ni-free stainless steels to avoid sensitization (in cluding ‘Panacea’
(FeCrMn base system).
� 440C & 420 Ferritic stainless steels for instruments (FeCrMoC).
� Future specialist products? Ti powders/NiTinol Powde rs
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Dental Applications
Introducing Carriere LX™. The innovative new passive self-ligatingbracket system.
� Features a simple locking mechanism located in the bracket face.
The Carriere LX opens with an instrument and closes securely manually enabling quick and easy archwire changes an d faster treatment time.
� Low profile self-ligating bracket provides greater p atient comfort. A micro-etched bonding base offers increased bond s trength.
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Carriere Distalizercourtesy MPIF, World Class Technology
Description: a complex design in two pieces: 1. A posterior pad with a socketand an interior rod with a ball on one end and 2. A pad with a hook on top at the other end. The ball is pressed into t he socket in the posterior pad to make the final assembly, which com es in three sizes, each with a left - and a right-hand version. Made from a nickel-free stainless steel, the parts are formed t o a density of 7.6 g/cm³ and exhibit a yield strength of 550MPa, an ult imate tensile strength of 670MPa, and a 22% elongation.
Description: The system consists of multiple parts made from 17- 4PH stainless steel. The parts have an ultimate tensile strength of 840MPa and a yield strength of 720MPa. Elongation is 10% and the heat-treated hardness range is 38–42 HRC. The heat-treated ultim ate tensile strength is 1300MPa and the heat-treated yield stre ngth is 1120MPa. The tube system was first introduced in the all-met al Damon self-ligating orthodontic appliance. When in full product ion, this application will total more than 12 million parts a nnually.
Damon 3 Molar Buccal Tubecourtesy MPIF, FloMet, Inc.
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Thornton Adjustable Positioneralleviates sleep apnea/snoring
The TAP® is a medical device that treats sleep disordered breathing. It alleviates snoring and sleep apnea by holding the mandible forward during sleep to prevent the tongue and soft tissue of the throat from collapsing into the airway. Based on the same principle as cardiopulmonary resuscitation (CPR). The airway must be open to allow air to pass through the throat.
The metal components in the TAP® are madefrom 316 surgical stainless steel. Outer shellsare thermoplastic orthodontic polycarbonate
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Micro - MIM� Micro- MIM takes MIM to another level where Osprey p owders less than
5 microns in diameter are used to produce “micro” pa rts
� Review of MIM papers presented at the conference.� Micro Metal Injection Moulding - Quality Assurance i n Series ProductionAstrid Rota, Philipp Imgrund, Lutz Kramer, Ralf Mey er, Janne HaackFraunhofer IFAM, Germany
316L stainless steel ear implant
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Rapid Prototyping/Manufacture
� Selective Laser Sintering
� Infiltration
� Selective Laser Melting
� Electron Beam Melting
� Direct Metal Deposition
� Laser Engineered Net Shapes
� Metal Powder Screen-Printing Schematic illustration of a SLM machine.
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Medical Applications � Scanning & Digitizing
� Rapid Machining Centres
� Selective Laser Melting for Dental Applications
� Scanning & Digitizing
� CoCrMo (F75) powder products are now CE Marked
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Selective Laser Melting- an Emerging Technology
� Biomedical applications
• Orthopaedic implants, joint implant prostheses, pos t-tumour bone reconstruction all using structures which mimic hum an bone
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Electron Beam Prototyping
Using CT scan data, it is possible to build custom designed
implants that perfectly match the shape of the pati ent’s bones.
Arcam has received an order from an Italian manufacturer in the biomedical field. The system will be used for volume production of orthopaedic implants. (Q4 2006)
Maxillo-facial reconstructionF75 and Ti alloy products
Sequential Electron Beam melting of powder bed
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Quick-fit connectors
for oil pipe-lines
• Full range of stainless steel and cobalt alloy powders for critical applications.
• Option for fine particle size to reduce defect size.
HIP Powders
Extruder Barrel Coating
Sinter Beads
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
� Commercially Pure Titanium (MIM-Ti)� 0.2%Yield Strength 420 MPa
� Tensile Strength 500 MPa
� Elongation 20%
� Hardness (HV) 190
� Titanium Alloy (MIM-Ti-6Al-4V ELI)� 0.2%Yield Strength 700 MPa
� Tensile Strength 800 MPa
� Elongation 15%
� Hardness (HV) 300
Mechanical Properties of Ti-MIM
Data courtesy of TiJet Medizintechnik, Germany
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
� Cochlea implants
� Heart tri-valve
� Orthopaedics
� Hips, knees, studs
� Small joints.. Fingers, toes
� Dental.. Pegs
� Porous structures for bone ingrowth
� Maxillo-facial.. Mandible products
� Tools.. Drills & burrs, reamers, forceps, scissors
� Mini-screws in Ti for high precision crown implants that allow bone in-growth
� Excellent biocompatibility but concerns over availability of affordable, good quality feedstock & dificulty of controlling MIM process reproducibly with Ti.
Titanium MIM
courtesyTiJet Medizintechnik
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
New developments
� MicroMIM powders; 80% -5 microns giving finer resolu tion
& enabling further miniaturisation of components
� New alloy systems – Ni-free ranges: alternatives to Panacea
� MIM for in vivo implants – bone repair
� Alloys with controlled modulus for more comfortable orthodontics
� Ti alloy powders
� NiTinol Powders
� Combination of powder technologies to make hybrid s tructures
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Conclusions� MIM has overtaken investment casting of orthodontic s brackets with better
precision, lower cost and greater opportunity for m iniaturisation.
� ~7% by volume of the MIM market today is in medical & dental applications but the % is greater in value terms. Primary market is N.America.
� Key alloys are F75 (CoCrMo), 17-4PH and 316L (ELI) plus low Ni stainless steels. Properties equivalent to wrought can be ach ieved by MIM.
� Cost of metal powder is a small fraction of finishe d part cost. Rapid expansion of MIM possible through greater awareness of advantages.
� Growth of Ti in MIM hampered by cost and complexity of processing.
� CAD to Laser and CAD to Electron Beam processes are being adopted more widely for manufacture of bespoke caps, bridges etc .
� Control of particle size distribution to achieve go od flow and therefore good part conistency and also to improve on resolution of finished parts.
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Metal Powder for Medical & Orthodontic Applications
Sandvik Osprey Ltd is part of the US$10 billion Sandvik Group, with 40,000 employees operating in more than 130 countries. The Sandvik Group is a high technology global engineering group with advanced products marketed worldwide. As a leading producer of metal powders for high performance end uses, Sandvik Osprey has developed a range of gas atomised metal powders specifically
designed for medical and orthodontic applications. These include applications in orthodontic brackets, orthopedic implants and surgical instruments. Manufacturing techniques exploit the latest high precision and net shape powder metallurgy processes including:
• Metal Injection Moulding (MIM) • Selective Laser Sintering (SLS) • Selective Laser Melting (SLM) • Electron Beam Melting (EBM) • Laser Engineered Net Shapes (LENS) • Sintered Metal Beads (SMB)
The Gas Atomised Powder Range includes: Cobalt Alloys -
• ASTM F75 (Co 29Cr 7Mo) • ASTM F90 (Co 20Cr 15W 10Ni) • MP35N UNS R30035
Stainless Steels -
• 17-4PH - UNS S17400 • 316L - UNS S31603 & ISO 5831-1 • 440C - UNS S44004
These powders have a spherical morphology and therefore excellent
flow characteristics and are available in a wide range of particle size distribution, from < 5 µm to < 250 µm powder particle diameters. The powder size distribution is tailored to the application requirements, be they fine powders for MIM and Rapid Prototyping, or coarse powders for Coating or Hot Isostatic Pressing (HIP) applications. They are manufactured using the highest quality raw materials, including vacuum cast feedstock and handled within a clean room environment with dedicated equipment.
Recommendations are for guidance only, and the suitability of a material for a specific application can only be confirmed when the actual service conditions are known. Continuous development may necessitate changes in the technical data without notice.
SANDVIK OSPREY LTD
Red Jacket Works, Milland Road, Neath, SA11 1NJ, United Kingdom Tel: +44 - (0)1639 - 634121 Fax: +44 - (0)1639 - 630100
E-mail: [email protected] Website: www.smt.sandvik.com/osprey
30/03/2007
Sandvik Osprey / BASF Meeting – 14 March 2006
Sales & Service
www.smt.sandvik.com/osprey