3D-printing techniques in a medical setting : a systematic literature review

Background: Three-dimensional (3D) printing has numerous applications and has gained much interest in the medical world. The constantly improving quality of 3D-printing applications has contributed to their increased use on patients. This paper summarizes the literature on surgical 3D-printing applications used on patients, with a focus on reported clinical and economic outcomes. Methods: Three major literature databases were screened for case series (more than three cases described in the same study) and trials of surgical applications of 3D printing in humans. Results: 227 surgical papers were analyzed and summarized using an evidence table. The papers described the use of 3D printing for surgical guides, anatomical models, and custom implants. 3D printing is used in multiple surgical domains, such as orthopedics, maxillofacial surgery, cranial surgery, and spinal surgery. In general, the advantages of 3D-printed parts are said to include reduced surgical time, improved medical outcome, and decreased radiation exposure. The costs of printing and additional scans generally increase the overall cost of the procedure. Conclusion: 3D printing is well integrated in surgical practice and research. Applications vary from anatomical models mainly intended for surgical planning to surgical guides and implants. Our research suggests that there are several advantages to 3D- printed applications, but that further research is needed to determine whether the increased intervention costs can be balanced with the observable advantages of this new technology. There is a need for a formal cost-effectiveness analysis

Soft and Hard Implant Fabrication Using 3D-Bioplotting TM

At the Freiburger Materialforschungszentrum we have developed a new process (3DBioplotting TM) that permits most kind of polymers and biopolymers to be used in 3D scaffold design, including hydrogels (e.g. collagen, agar), polymer melts (e.g. PLLA, PGA, PCl) and twocomponent systems (e.g. chitosan, fibrin). Cells can be incorporated within the construction process, making this an ideal Rapid Prototyping technique for Organ Printing. Tailor-made biodegradable soft or hard scaffolds can so be fabricated in a short time using individual computer-tomography data from the patient. In-vitro tests showed promising results and in-vivo experiments are now under observation.Mechanical Engineerin

Rapid manufacturing- state of the art, analysis and future perspectives

Layer based manufacturing system often referred to as Rapid Prototyping (RP) have been in existence for 22 years, in the past 5 years Rapid Manufacturing (RM) has emerged from these RP systems to produce functional and structural customer focused end use components and products. This keynote paper will review the current range of technologies for metallic systems, it will also evaluate the operating principles, features, potential and limitations of current commercially available systems. Rapid Manufacture is increasingly being used for high value difficult to manufacture components with a new set of design rules required to fully exploit the RM systems inherent characteristics. A case studies approach will be used to show the benefits and pitfalls this new design freedom can provide designers

Ecological IVIS design : using EID to develop a novel in-vehicle information system

New in-vehicle information systems (IVIS) are emerging which purport to encourage more environment friendly or ‘green’ driving. Meanwhile, wider concerns about road safety and in-car distractions remain. The ‘Foot-LITE’ project is an effort to balance these issues, aimed at achieving safer and greener driving through real-time driving information, presented via an in-vehicle interface which facilitates the desired behaviours while avoiding negative consequences. One way of achieving this is to use ecological interface design (EID) techniques. This article presents part of the formative human-centred design process for developing the in-car display through a series of rapid prototyping studies comparing EID against conventional interface design principles. We focus primarily on the visual display, although some development of an ecological auditory display is also presented. The results of feedback from potential users as well as subject matter experts are discussed with respect to implications for future interface design in this field

Research Towards High Speed Freeforming

Additive manufacturing (AM) methods are currently utilised for the manufacture of prototypes and low volume, high cost parts. This is because in most cases the high material costs and low volumetric deposition rates of AM parts result in higher per part cost than traditional manufacturing methods. This paper brings together recent research aimed at improving the economics of AM, in particular Extrusion Freeforming (EF). A new class of machine is described called High Speed Additive Manufacturing (HSAM) in which software, hardware and materials advances are aggregated. HSAM could be cost competitive with injection moulding for medium sized medium quantity parts. A general outline for a HSAM machine and supply chain is provided along with future required research

Development of a regenerative pump impeller using rapid manufacturing techniques

This paper presents a method of rapid manufacture used in the development of a regenerative pump impeller. Rapid manufacturing technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry. Ten modified impeller blade profiles, relative to the standard radial configuration, were evaluated with the use of computational fluid dynamics and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles, using conventional milling techniques, is a considerable challenge for skilled machinists. The complexity of the modified blade profiles would normally necessitate the use of expensive CNC machining with 5 asis capability. With an impeller less than 75mm in diameter and a maximum blade thickness of 1.3mm, a rapid manufacturing technique enabled production of complex blade profiles that were dimensionally accurate and structurally robust enough for testing. As more advanced rapid prototyping machines become available in the study in the future, e.g. 3D photopolymer jetting machine, the quality of the parts, particularly in terms of surface finish, will improve and the amount of post processing operations will reduce. This technique offers the possibility to produce components of increased complexity whilst ensuring quality, strength, performance and speed of manufacture. The ability to manufacture complex blade profiles that are robust enough for testing, in a rapid and cost effective manner is proving essential in the overall design optimisation process for the pump

A method to Formalise the Rapid Prototyping Process

Facing the increasing complexity of the product design area, (reduction of cycle times, introduction of simultaneous engineering, introduction of digital mock-up, ... ) a research department which wants to define a rapid prototyping process is confronted to the problem of the tools’ choice. Therefore, we will propose in this article, a method allowing to conceive such a process. In a first chapter, we present the rapid prototyping area in the product design environment, in a second chapter we will propose our method illustrated by an industrial case

Rapid manufacturing technique used in the development of a regenerative pump impeller

This paper presents a method of rapid manufacture used in the development of a regenerative pump impeller. Rapid manufacturing technology was used to create complex impeller blade profiles for testing as part of a regenerative pump optimisation process. Regenerative pumps are the subject of increased interest in industry. Ten modified impeller blade profiles, from the standard radial configuration, were evaluated with the use of computational fluid dynamics and experimental testing. Prototype impellers were needed for experimental validation of the CFD results. The manufacture of the complex blade profiles using conventional milling techniques is a considerable challenge for skilled machinists. The complexity of the modified blade profiles would normally necessitate the use of expensive CNC machining with 5 axis capability. With an impeller less than 75 mm in diameter and a maximum blade thickness of 1.3mm, a rapid manufacturing technique enabled production of complex blade profiles that were dimensionally accurate and structurally robust enough for testing. As more advanced rapid prototyping machines become available in the study in the future, e.g. 3D photopolymer jetting machine, the quality of the parts particularly in terms of surface finish will improve and the amount of post processing operations will reduce. This technique offers the possibility to produce components of increased complexity whilst ensuring quality, strength, performance and speed of manufacture. The ability to manufacture complex blade profiles that are robust enough for testing, in a rapid and cost effective manner is proving essential in the overall design optimisation process for the pump