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Patient Matched Implant for Cranioplasty

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Patient Matched Implant for Cranioplasty

To have a patient matched implant for cranioplasty, the customizable nature of Patient specific implant lends itself to manufacture, ship, and autoclave at a competitive price point. Custom made implants benefit from many of the same advantages as Digital Surgery Planning (for example, CMF reconstruction) in that the advanced preparation can reduce operating room time, reduce risk, and help improve surgical outcomes.
Aesthetically the titanium mesh needs to be hand-bent to best fit the patient, but continual bending of titanium can contribute to micro-fractures that may compromise material strength. Work-hardening of titanium can lead to implant failure, but in the case of custom made implants, the surgeon could avoid the risk of work-hardening by selecting a 3d printed implant.

Cranial Custom Made Implant

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Cranial Custom Made Implant

Custom made implant for the reconstruction of craniofacial defects have gained importance due to better performance over their generic counterparts. This is due to the precise adaptation to the region of implantation, reduced surgical times and better cosmetics of additively manufactured implants.

Advances in manufacturing processes for direct 3D printing of Patient specific implants has eliminated the constraints of shape, size and internal structure and mechanical properties making it possible for the fabrication of titanium implants that conform to the physical and mechanical requirements of the region of implantation.

In the vast majority of cases, precise symmetric reconstruction of maxillofacial defects remains an unsolved problem for craniofacial surgeons. Patient specific implants have contributed considerably to improvement in the accuracy and reliability of facial rehabilitation, rapidly becoming an irreplaceable part of the surgical armamentarium.

3d printed implants could be an advantageous and promising alternative to the use of other alloplastic materials. Moreover, custom made implants has the potential not only to achieve predictable correction for congenital or acquired deformities but also to serve a merely cosmetic purpose.

A titanium custom made chest wall implant could be a viable alternative for patients who had large chest wall tumors.

3D Printed Implants

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Adaptation of bone implants with 3-D printing

One way to minimize the disparity between the material properties of the bone and 3D printed implants (patient specific implants) is match the mechanical properties and the stiffness. By inserting pores in the 3D printed titanium implants, the elastic modulus of the material can be reduced and bring closer to bone.
Using additive manufacturing techniques, 3d printed titanium implants with desired porosity can be predesigned which are also tailored for wall thickness, pore size, and bulk modulus.

For a patient-matched cranioplasty, the customizable nature of Patient specific implant lends itself to manufacture, ship, and autoclave at a competitive price point.  Custom made implants benefit from many of the same advantages as Digital Surgery Planning (for example, CMF reconstruction) in that the advanced preparation can reduce operating room time, reduce risk, and help improve surgical outcomes.

Porous Patient Specific Implants (PSI) are comparable to cortical bone and designed from patient scan data to create a customized, patient-specific solution. 3d printed implants are commonly used as an alternative to bone flaps to fill a defect or void in the cranial skeleton.

With extensive experience in computer-aided design and equipped with the latest 3D technologies, Bonash can supply you with a wide range of custom made implant.

Use of CAM/CAM in Implants Designing

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Use of CAM/CAM in Implants Design

CAM/CAM systems have enabled us the ability to design and manufacture custom implants at an acceptable cost in a reasonable time. Additive manufacturing (3D printing) technologies lend themselves to manufacturing of complex 3d printed patient specific (custom made) implants without any barriers of design constraints.

Computer-aided manufacturing (CAM) is the use of software to control machine tools and related ones in the manufacturing of workpieces. This is not the only definition for CAM, but it is the most common CAM may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage. Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is used in many schools alongside computer-aided design (CAD) to create objects.

Metal 3d printing uses bio-compatible implantable materials as pure titanium, Ti6Al4V and chrome cobalt and facilitate the direct production of custom made implants (patient specific implants) with engineered properties that match properties of the tissues at the region of implantation.

3D Printed Implant Manufacturing

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3D Printed Implant Manufacturing

Using the CT scans, Bonash is able to make patient specific (custom made) 3d printed implant despite the substantial damage to patient’s skull. Researchers see 3D printing as beneficial in very cases as the implant fits more snugly due to customization and less time is spent in the operating room.

In the end, the patient looks better too with the incision scar hiding behind the hair line. They are also resistant in the case of an impact. The surgery to insert a typical 3D printed implant (custom made implant) took only about four hours, and was very successful.

The use of 3Dprinting has enabled us to work with patient specific model with a fully embedded implant. In the era of patient specific implant designs, using topology optimization method in order to find the structurally optimized solution, can eliminate the uncertainty of choosing heuristic shapes for critical surgeries like mid-face reconstruction.

3D Printing promises to produce complex biomedical devices according to computer design using patient specific anatomical data. Since its initial use as pre-surgical visualization models and tooling molds, 3D Printing has slowly evolved to create Patient specific (custom made) implants, scaffolds for tissue engineering and etc.

Customized Implants

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Customized Implants Based on Computerized Design

3D Printing promises to produce complex biomedical devices according to computer design using patient specific anatomical data. Since its initial use as pre-surgical visualization models and tooling molds, 3D Printing has slowly evolved to create customized implants (patient specific implant), scaffolds for tissue engineering and etc.
Different type of metal 3D printing methods has allowed for the design and fabrication of 3D printed titanium implants which can be patient specific. The integration of computer aided design, advanced imaging techniques (i.e. magnetic resonance imaging and computer tomography), and additive manufacturing, has advanced fabrication of custom made implants.

Using Bonash designing systems, help the surgeon to be prepared for OR.

3D Printed Implant

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When it comes to shoulder joint replacements, a patient specific implant can often be more suitable than standard solutions – particularly in cases that involve severe bone defects. Bonash offers surgeons 3D printed implant for cases of reverse shoulder arthroplasty.

Our additively manufactured implants bring predictability to your work. Being able to see the anatomy in 3D beforehand enables you to run through a more complete planning exercise. This reduces the elements of surprise you might otherwise meet in the operating room.

The greatest advantage that 3D printers provide in medical applications is the freedom to produce patient specific medical implants and equipment. For example, the use of 3D printing to customize prosthetics and implants can provide great value for both patients and physicians.

3D printed implant, fixtures, and surgical tools can have a positive impact in terms of the time required for surgery, patient recovery time, and the success of the surgery or implant. It is also anticipated that 3D printing technologies will eventually allow drug dosage forms, release profiles, and dispensing to be customized for each patient.

Custom Made Implant Manufacturing

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Custom Made Implant Manufacturing

Introduction of direct digital manufacturing technologies that enable the fabrication of porous 3D printed implants with lattice and solid structures in one go from patient specific data has opened up a new horizon for the next generation of custom made implant.

In the very recent past ushering of metal additive manufacturing has introduced the direct fabrication of the titanium implants without the need for the template. This custom made implant will aim to confirm to the normalized shape of the part it replaces, with mechanical properties being close to that of the region of implantation.

In comparison to standard implants, 3d printed implants have many benefits:

  • Superb shape matching
  • Shorter surgery time and recovery time
  • Can be used to reconstruct any skeleton structure
  • Not palpable to the patient
  • Possibility of obtaining very complex implant geometry
  • High level of osseointegration by using scaffold structure inside the implant

Titanium 3D Printed Implants

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Titanium 3D Printed Implants

There are few material that used in manufacturing of patient specific implants or generally as a solution for craniofacial reconstruction (Such as PEEK and PMMA). Titanium and its famous alloy – Ti6Al4V – are one of the most popular materials used for the production of 3d printed implants, because of its light weight, high strength, highly bio compatibility and very good osseointegration. 3D printed Implants do not interfere with computed tomography imaging and magnetic resonance imaging procedures which is a critical point due to postoperative follow up and cares.
Titanium 6Al4V (Grade 5) and 6Al4V ELI (Grade 23) are standard titanium alloys used for the manufacture of patient specific implants (custom made implants). There is also the possibility to manufacture implants additively from pure titanium (Grade 4), but the CPT (Commercially Pure titanium) mostly is used to manufacturing dental implants and in other field such as CMF (Craniomaxillofacial) or orthopedics surgeries, Ti6Al4V is the most popular material.

Application of customized implants

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Application of customized implants

Porous Patient Specific Implants (PSI) or customized implants are comparable to cortical bone and designed from patient scan data to create a customized, patient-specific solution. 3d printed implants are commonly used as an alternative to bone flaps to fill a defect or void in the cranial skeleton.
Neurosurgeons have a wide selection of cranioplasty products to choose from, including PEEK polymer, PMMA, and titanium. New products are gradually coming to market, but few boast the clinical specifications of customized titanium materials. Many doctors prefer additively manufactured titanium implants because of the material durability and the ease of use in the OR.