Medical device prototyping and rapid manufacturing are the foundation of your medical product design and development process. In medical field, the versatility and precision offered by 3D printing technology has completely revolutionized the manufacturing of medical devices. 3D printing is an additive layering process that allows individual components to be produced quickly that can easily create complex geometric shapes for applications such as prosthetics or medical models. This rapid prototyping method allows for quick and inexpensive iterations of the design for efficient debugging, which makes it very useful for the early evaluation of new medical parts.
Medical prototyping has made it possible for professionals to explore different avenues that were previously left uncharted. From customized prosthetics and orthopedics to bioprinting for regeneration to surgical and dental procedures, 3D printing holds incredible potential to transform. Further in this article we will explore how 3D printing revolutionizing medical prototyping and manufacturing of medical instruments.
Customized Prosthetics and Orthopedics
The process of creating customized prosthetics and orthopedics begins with a thorough assessment of a person’s anatomy and unique functional requirements. The process starts with detailed imaging of the affected areas, advanced imaging techniques such as 3D laser scanning or CT scans are used to obtain precise measurements. The designers use these customs data with the help of 3D modeling software such as CAD modeling and analysis software to optimize a 3D detailed design for printing purposes.
Once the digital design is complete, the next step involves selecting appropriate 3D printing technology and materials. With the use of additive manufacturing techniques such as Selective laser sintering (SLS) and fused deposition modeling (FDM) engineers can manufacture complex and intricate structures with tight tolerance and high precision. In the SLS method a high-sintered laser beam fuses powdered material layer by layer as per digital designs. This process is mostly used when we are dealing with prosthetic components and orthopedic implants. Its material diversity and high-powered laser help to create intricate and complex designs of these machines.
Fused Deposition Modeling (FDM) is mostly employed for medical prototyping and low-cost manufacturing. FDM is a cost-effective alternative, it uses a heated nozzle that works by extruding thermoplastic filaments and depositing material layer by layer in built form. For the manufacturing of prosthetics and orthopedics like joints, sockets, plates and screws biocompatible materials such as titanium, cobalt-chromium alloys, and medical-grade plastics are often used. The material selection in the manufacturing process is highly specific as per strength, durability, and compatibility needed.
Customized Surgical Instruments by Binder Jetting
Highly precise and customized surgical parts such as Surgical forceps, handles and tweezers made from binder Jetting printing technology has garnered significant attention due to their exceptional precision and efficiency. Binder jetting technique is ideal for manufacturing lightweight yet durable instruments. In binder jetting technique the material is spread on a pre build platform in powder form.
This powdered material is then bind together thorough a print head that can selectively deposits a liquid binding agent on the powder material as per programmed. The binding agent is usually a polymer or an adhesive solution that adhere the powered material in solid form The process is completed in layer-by-layer form, once a layer is completed, another layer of powdered material is speeded and by repeating the process the entire design is manufactured. The print head is moved on the whole platform from one side to other covering the whole area. It is a step wise process, as per the printed design a geometry is formed and excessive material is removed and process is repeated again for competition.
This advance printing technology is suitable for customized surgical instruments like retractors and speculum. where a quick rapid medical prototyping turn out is needed with precise medical standards. In contrast to traditional machining where once need to cut a whole block of material to desired shapes. Binder jetting manufacturing lead time and flexibility to work with a wide range of materials like ceramics, cobalt, titanium and composites is well-suited for manufacturing.
Bioprinting for Tissue Engineering and Regenerative Medicine
The bioprinting of skin grafts began with the collection of cells such as dermal fibroblasts and epidermal keratinocytes from patients’ own bodies or donor sources, as per medical recommendations. These cells are further processed, cultured, and expanded in vitro so that a sufficient amount is available for printing. Special 3D bioprinters mostly extrusion-based or inkjet printers, equipped with temperature-controlled chambers for maintaining cell viability and precise dispensing systems used for cell deposition are used.
In the meantime, a biocompatible scaffold material is also prepared for the process. This material is used as a supportive matrix for the cells during the printing process and is often available in the form of hydrogels or bio-inks. During the printing process, layers of scaffold material and cells are precisely deposited as programmed so that one can obtain the desired skin structure. The use of scaffold material in manufacturing helps a lot in providing structural support to growing cells and maintaining structural integrity.
Precise 3D-Printed Dental Crowns and Bridges
A precise design is the most important factor in professional dental crowns and bridges. CAD software’s design phase allows the manufacturers to do meticulous customization like bite alignment, occlusal surfaces, and restoration margins with highly specific customization. These designs are carefully analyzed from software and through patient feedback before manufacturing.
Once the design is finalized it is transferred to a 3D printer for manufacturing purposes. For dental applications, manufacturers usually prefer Digital Light Processing (DLP) printing techniques. This preference is due to the ability of DLP to cure entire layers of resin simultaneously, as a result, the manufacturing time is significantly reduced while maintaining the high quality of accuracy. However, in customized crowns with high surface finishing and intricate designs, UV laser layer-by-layer deposition through the SLA technique will assist in intricate dental designs with smooth, precise contours.
In both techniques, precise control over printing process such as layer thickness and curing times will provide faithful replication of the patient’s dental anatomy. This will not only provide an optimal fit but also minimize the need for extensive adjustments during treatments. The ability of 3D printing to offer a versatile material range will improve the restoration’s shade and transparency in the products compared to traditional machining. Ceramics in these designs offer translucency and resilience while resigns are used as they provide flexibility and ease of handling.
Conclusion
3D printed customized solutions are rapidly changing the medical fields. The manufacturers who are able to adopt the technology revolution, by doing R&D on materials and digital manufacturing techniques are able to compete the market. As the market is continually evolving so before making a decision, to go for 3D printing medical prototyping one should be well aware of the capability of the machine shop he is choosing.
Also Read: Understanding 3D Printing
