3D-printed implants accelerate the healing process

Challenges

Spinal cage implants are usually equipped with holes, through which they are screwed to bones during surgery. Caselli and his team decided not to use holes, but rather to create spinal cages with a complex grid structure. "PEEK implants need holes, this is because the bones do not fuse with the plastic and therefore need to be mechanically connected", explains the CEO. "In contrast to this, the bones fuse with our implants without a problem thanks to the grid structure." The structure also increases their stability. A good idea that works, as proven by a study from Cambridge University: After just four to five days the bone is fused with the cage.

But that isn't enough. For the next generation, Tsunami is developing extendable cages. Doctors would therefore only need one standard size available and can adapt the implants individually. A few years ago, the Tsunami team had a new idea: The developers integrate a mechanical element directly in the cage. This allows the implants to be anchored directly in the spine. Without any screws. However, this pushes the 3D-printing systems used by Tsunami up to now to their limits.

Solutions

"When we develop new products, we want them to accelerate the healing process for patients and make work easier for the surgeons", says Stefano Caselli. That's why he sees cages with an integrated mechanism that anchors the implant directly in the bone, as an idea with a future. However, he cannot manufacture these with their current 3D-printing systems. "These cages are very complex, so it's not easy to print them in one layout." But Caselli does not give up so easily. He tested a TruPrint 2000 from TRUMPF and it worked! "We took the new product to the machine and were able to manufacture it easily with minimal parameter adjustments."

Implementation

Further tests confirmed the first impression, but quickly showed that Tsunami required a higher capacity. That is why the company exchanged the TruPrint 2000 for a TruPrint 3000. The universal medium-format machine is equipped with the multilaser option. With two 500 Watt lasers, Tsunami can create the cages twice as quickly in the Laser Metal Fusion process. Stefan Caselli stresses: "Due to the great build volume, we can print six of the implants consecutively - in one production step." Due to the smaller work area on the previous system, it was only possible to produce a maximum of four implants consecutively. "With the TruPrint 3000, we could even increase to ten implants. We have already doubled our production volume today - and could even triple it, if we stack the cages even higher."

As well as the cages, Tsunami uses the TRUMPF system to produce pedicle screws, which are used to stabilize the spine. "We developed a special screw concept, which is manufactured using 3D-printing processes and scores points for its improved biocompatibility. The screw has a similar porosity to bones, which aids the healing process and is less damaging during X-rays." The screws produced using additive manufacturing also have a 15 to 20 percent higher level of mechanical stability in comparison to conventionally produced screws.

Forecast

Stefano Caselli is satisfied with the transfer of the cage onto the TruPrint 3000. Now he wants the opportunity to further utilize the system and increase the output: "We are still learning every day", he says. "We are currently only using ten percent of the machine capacity. We currently lose around one day at the weekend for example, as the order is finished on Sunday morning but is not further processed immediately. We want to change that by better organizing our production processes." Then he wants to venture into new markets with his implants. With the TruPrint 3000, he has found the suitable and reliable technology to do so.

Updated: 2025-05-20