EOS additive manufacturing typical application of cranial implants

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How can additive manufacturing technology help create surgical cranial implants that perfectly match the human body? Cranial implants must meet the most stringent criteria, depending on many factors. Due to the size of the pores in the bone structure, the most important is the combination of biological function in the brain tissue and the lowest possible heat dissipation. In fact, titanium has good compatibility with the human body. Despite this, there is still danger: as a metal, once it is fully exposed to the sun, it will generate a lot of heat in the human body. Another factor is that tissue fluid from the brain cannot penetrate the titanium structure. In the requirements specification, the doctor also specified a special post-implant manufacturing process. Only controlled post-processing, especially in terms of cleaning, can improve component utilization in the medical sector. This is extremely important because the particles can be separated from the body by the slightest movement, leading to the possibility of infection or rejection.

In this case, an Argentine patient required a skull implant after a stroke-related surgery. The project requires all relevant factors to be as complete as possible: the highest precision and compatibility combined with a variety of biological functions.

Only porous structures can meet the necessary characteristics. The implant of the lattice structure is fixed to the skull by an integrated screw-in fixture, which helps the liquid to flow therethrough and contributes to its fusion with the bone tissue of the skull itself. More importantly, this design has a thermal insulation effect that minimizes the possibility of heat spreading into the cranial cavity.

DANIEL FIZ, CEO of NOVAX DMA, has a deep memory. “Time plays an important role in this. In any case, the patient should accept the implant as soon as possible. As soon as we know the size information, we start manufacturing.” When the CAD work is over, ALPHAFORM begins to manufacture the implant. . In actual production, they used EOS's EOSINT M 280. Manufacturing time only takes a few hours.

“We have successfully completed many products with the EOS system,” said CHRISTOPH ERHARDT, Director of Additive Manufacturing at ALPHAFORM AG. “We are proud of this implant, not only because of the precise realization of the shape, but also because we are able to optimize the cleaning process.” Especially for porous structures, the internal void space is small and extremely difficult to clean. This process is relatively sensitive. Basically, ALPHAFORM uses a multi-step cleaning method of friction and mechanical cleaning, rinsing and ultrasonic washing to achieve the medically required level of purity.

Tailor-made, perfect implants meet the individual needs of a specific clinical situation. The porosity level reaches 95%, which means that the liquid can flow with as little resistance as possible. In addition, the bone tissue is able to penetrate and grow with the outer edge of the implant. At the same time, the stability of the material is sufficient to return the patient to the desired daily life. The regular lattice structure also has the required thermal conductivity, so patients can enjoy the sun.

Time plays the most important role in this process. If time to market is an important strength in additive manufacturing in an industrial environment, it is even more important in the medical field. The data was prepared, then manufactured, and it took only two and a half days. The rest of the time is allocated to various processes such as logistics and coordination. CHRISTOPH ERHARDT and its team conducted extensive testing, including particle and cytotoxicity testing. They also performed gas chromatography analysis. “All analyses have proven that implants produced by additive manufacturing technology meet the requirements for stabilization and protection of the patient's skull. Surgery took place in May 2014, which took an hour and a half, and the procedure went very smoothly. Two days later the patient was discharged, wounds Healed within three weeks. Since then, there have been no complications," the expert confirmed. EOS's innovative technology largely ensures that people who are sick or injured can live an unrestricted life.

CHRISTOPH ERHARDT, Director of Additive Manufacturing at ALPHAFORM AG, said: “For us, additive manufacturing and EOS technology are all about achieving the same goal. Both our own and our customers can apply to applications that can be implemented using EOS systems. Sexuality and quality production are awe-inspiring. This is also the case in this case. We can help people who have been seriously injured to live a normal life for a long time."

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