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Use case: Additive manufacturing of CMF implants | TRUMPF

Additive manufacturing of personalized implants for people with craniomaxillofacial (CMF) deformities

CMF implants | Ti6Al4V ELI | TruPrint 2000

Tumour patients and patients with congenital or acquired malformations caused by trauma or atrophy often benefit greatly from an individualized patient solution (IPS). Additive manufacturing now makes it possible to produce high-quality implants with fast availability at acceptable costs – even for one-off lot sizes. Optimum patient care is guaranteed. The implants are based on the patient's anatomical data, which means faster recovery and significantly fewer surgical procedures. In many cases, the implant can even be subjected to loads immediately after surgery.

Highly cost-effective

One-off medical devices can be produced cost-effectively. TruPrint machines and systems provide the ability to scale production from one-off to mass-produced medical devices.

More design freedom

Benefit from individualized part design adapted to the patient's anatomy. Lattice and porous structures can also be incorporated into the implant to improve fluid and heat exchange.

Fewer surgical interventions

Additive manufacturing enables the patient's anatomy to be reconstructed without bone augmentation. This means fewer surgical procedures and therefore less stress for the patient.

Quick availability

Individual implants can be quickly produced "on-demand" to get them promptly to the operating theatre.

Examples of personalized implants in oral and maxillofacial surgery

Skull plate made of Ti6Al4V ELI and a lattice structure

  • Restoring form and function
  • Lattice structure for fluid exchange and heat dissipation

Orbital implant made of Ti6Al4V ELI with a wall thickness of 0.3 mm

  • Drainage function
  • Atraumatic implant edge

Jaw implant made of Ti6Al4V ELI with immediate functionality

  • Loading possible immediately after surgery
  • No bone augmentation necessary
  • Reduction of rehabilitation and total treatment duration
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How is a CMF implant created using laser metal fusion?

Individualized series production of high-quality implants for the medical sector is a key area of application for additive manufacturing. Individualized patient solutions require prompt delivery of the implant to the operating theatre. The complete production process, including data generation using imaging techniques (CT), 3D printing and post processing, usually takes up to a week. Availability can however be improved by adding a second laser to the TruPrint 2000. 3D printer productivity can then be increased with a positive impact on part costs. Manufacturing medical devices, especially Class III devices, requires certified equipment and a validated process. TRUMPF's certification support follows an established procedure to prepare all necessary information for the TruPrint 2000 machine and its periphery so that they can be operated in a certified environment. Smart industrial monitoring systems and advanced powder handling technologies help to monitor the process and to monitor material and equipment quality.

Component facts & figures

  • Component dimensions: Jaw implant: 176 mm x 94 mm x 135 mm, Pre-prosthetic implant: 55 mm x 55 mm x 55 mm, Orbital implant: 41 mm x 18 mm x 34 mm
  • Total build time (all components / substrate plate): 29 h (multilaser), 44 h (single laser)
  • Layer thickness: 30 µm
  • Number of layers: 4677
  • Weight: Jaw implant: 113 g, Pre-prosthetic implant: 10 g, Orbital implant: 1 g
  • Volume: Jaw implant: 25.5 cm³, Pre-prosthetic implant: 2.3 cm³, Orbital implant: 0.3 cm³
  • Customer: KARL LEIBINGER MEDIZINTECHNIK, a KLS Martin Group company

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