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Additive manufacturing of personalized implants for craniofacial applications

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 your 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

One-off productions can be manufactured on request within a short period of time to get them promptly to the operating room.

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

How is a CMF implant created using laser metal fusion?

Individualized series production of high-quality implants is a main application area for additive manufacturing in medical technology. Individualized patient solutions require prompt delivery of the implant to the operating room. The complete manufacturing process, including data generation using imaging techniques (CT scan), 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. The multilaser option increases productivity and can have a positive effect on the cost per part. Manufacturing medical technology products, particularly products from risk class III, requires qualified equipment and a validated process. TRUMPF offers extended services which support customers working in certified environments in questions of equipment qualification and process validation. The latest developments in process monitoring and a sophisticated concept for powder handling and preparation also contributes to the process and the quality of the powder and component.

Arrange your consultation today!

Do you also have a component that would be a good candidate for additive manufacturing? Would you like to know what savings and advantages you can benefit from with additive manufacturing? Then get in touch with us today to arrange an individual consultation with our experts.

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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


Do you want to use your TruPrint systems for production that requires certification? Our experts provide support for "Installation Qualification" (IQ) with an enhanced, standards-based installation process.

TruPrint 1000
TruPrint 1000

If you need to produce small series or prototypes using laser metal fusion, our compact TruPrint 1000 machine for 3D printing metal components is the ideal choice for you.

TruPrint 2000
TruPrint 2000

Are you looking for a profitable machine concept with outstanding printing results? The TruPrint 2000 meets these requirements exactly. With its full-field multilaser, consisting of 2 x 300 W (optionally 2 x 500 W) lasers, a beam diameter of 80 µm and a short recoating time, it delivers excellent results.

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