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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

Patient Specific Implant in Orthopedics

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Patient Specific Implant in Orthopedics

If there is one thing that surgeons appreciate more than anything else, it is predictability of the surgical outcome. Patient specific implant brings you that level of confidence, so you can concentrate on executing operations that can completely change a patient’s life.

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 implants such acetabular hip implants, shoulder implants and craniofacial implants, based on anatomical data from the patient and your requirements as a surgeon.

For an operation as vital to a patient’s everyday life as a hip implant, it makes sense to get the job done right first time. Unfortunately, patients with non-standard bone loss are often condemned to multiple surgeries (revision surgery), which can be avoided by 3d printed implants.

For challenging bone defects, a patient specific implant (custom-made implant) is the best way to match the medical considerations with the complex mechanical requirements of such an important moving part in the human body. Also we can modify the implants surface to reach an optimized surface in order to gain a perfect bone in-growth, better bone-integration and initial & long-term fixation.

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.

Custom Made Implants Advantages

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Perfectly matched shape of the custom made implants to the patient’s anatomy makes them the best response to the functional and aesthetic patients’ needs. Standard implants are limited and do not provide satisfying results while complex defects reconstruction or tumors resection. Additively manufactured patient specific implants are mostly used in facial reconstruction, oncologic and plastic surgery.
In comparison to standard implants, custom made 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.

Perfectly matched shape of the custom made implant to the patient’s anatomy makes them the best response to the functional and aesthetic patients’ needs. Standard implants are limited and do not provide satisfying results while complex defects reconstruction or tumors resection. Additively manufactured patient specific implants are mostly used in facial reconstruction, oncologic and plastic surgery. Perfectly matched shape of the custom made implant to the patient’s anatomy makes them the best response to the functional and aesthetic patients’ needs. Standard implants are limited and do not provide satisfying results while complex defects reconstruction or tumors resection. Additively manufactured patient specific implants are mostly used in facial reconstruction, oncologic and plastic surgery. Perfectly matched shape of the custom made implant to the patient’s anatomy makes them the best response to the functional and aesthetic patients’ needs. Standard implants are limited and do not provide satisfying results while complex defects reconstruction or tumors resection. Additively manufactured patient specific implants are mostly used in facial reconstruction, oncologic and plastic surgery. Perfectly matched shape of the custom made implant to the patient’s anatomy makes them the best response to the functional and aesthetic patients’ needs. Standard implants are limited and do not provide satisfying results while complex defects reconstruction or tumors resection. Additively manufactured patient specific implants are mostly used in facial reconstruction, oncologic and plastic surgery.

Custom Made Titanium Plates

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The shape of custom made titanium plates is defined during the preoperative planning, then the perfectly matched shape to patient’s anatomical structures is obtained during the production stage. 3d printed bone plates can be used in any case of bone fixations, in particular to reconstruct bones with complex 3D geometry, like pelvis or mandible.

In comparison to standard plates, custom made titanium plates have many benefits:
• Lack of internal stresses, which may occur as the result from the formation of standard plates in the operating room
• Better shape matching
• Individual screw placement which allows to avoid nerves, blood vessels or other structures damage
• Shorter operation time due to no need for plate formation during surgery
• Possibility to be used with surgical guides.

The shape of custom bone plates is defined during the preoperative planning, then the perfectly matched shape to patient’s anatomical structures is obtained during the production stage. 3d printed bone plates can be used in any case of bone fixations, in particular to reconstruct bones with complex 3D geometry, like pelvis or mandible.
In comparison to standard plates, additively manufactured titanium plates have many benefits:
Lack of internal stresses, which may occur as the result from the formation of standard plates in the operating room
Better shape matching
Individual screw placement which allows to avoid nerves, blood vessels or other structures damage
Shorter operation time due to no need for plate formation during surgery
Possibility to be used with surgical guides In comparison to standard plates, additivly have many benefits:
Lack of internal stresses, which may occur as the result from the formation of standard plates in the operating room
Better shape matching
Individual screw placement which allows to avoid nerves, blood vessels or other structures damage
Shorter operation time due to no need for plate formation during surgery
Possibility to be used with surgical guides

Personalized Titanium Prosthesis

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Personalized titanium prosthesis

Craniofacial segmental defects that are caused due to blast injury or tumor ablation require reconstructive procedures involving large bone replacement implants. Such defects remain a challenging problem for reconstructive surgeons as it is difficult to create a complicated 3D structure that satisfies significant functional and aesthetic roles of the mid face.
These defects are patient specific and the implants should depend on the loads and the dimensions of the missing bone defect. Advances in 3Dprinting technology have opened a new dawn in personalized titanium prosthesis design. Recently, an additively manufactured custom made implant has been successfully created and implanted in an infant using a 3D printer.

Craniofacial segmental defects that are caused due to blast injury or tumor ablation require reconstructive procedures involving large bone replacement implants. Such defects remain a challenging problem for reconstructive surgeons as it is difficult to create a complicated 3D structure that satisfies significant functional and aesthetic roles of the mid face.
These defects are patient specific and the implants should depend on the loads and the dimensions of the missing bone defect. Advances in 3Dprinting technology
Have opened a new dawn in patient specific implant design. Recently, an additively manufactured custom made implant has been successfully created and implanted in an infant using a 3D printer.
Craniofacial segmental defects that are caused due to blast injury or tumor ablation require reconstructive procedures involving large bone replacement implants. Such defects remain a challenging problem for reconstructive surgeons as it is difficult to create a complicated 3D structure that satisfies significant functional and aesthetic roles of the mid face.
These defects are patient specific and the implants should depend on the loads and the dimensions of the missing bone defect. Advances in 3Dprinting technology
Have opened a new dawn in patient specific implant design. Recently, an additively manufactured custom made implant has been successfully created and implanted in an infant using a 3D printer.

Highly Accurate Custom Made Implants for Patients

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In order to design a highly accurate implant for individual patients, Bonash proposes a software system that designs a patient specific hip implant by investigating the 3D anatomical geometry of the patient’s hip joints since bone cutting and alignment have to be achieved in 3D planes in surgical operation.
Accuracy of the additively manufactured prostheses is important to surgeons, and the capabilities of the custom made implants affect the outcome of design accuracy. Some of advantageous of titanium custom made prostheses are listed below:
• Ease of insertion of the implant stem in the canal of femur
• Successful positioning of implant in the hip joint

In order to design a highly accurate implant for individual patients, Bonash proposes a software system that designs a patient specific hip implant by investigating the 3D anatomical geometry of the patient’s hip joints since bone cutting and alignment have to be achieved in 3D planes in surgical operation.
Accuracy of the additively manufactured implants is important to surgeons, and the capabilities of the custom made implants affect the outcome of implant accuracy. Some of advantageous of titanium custom made implants are listed below:In order to design a highly accurate implant for individual patients, Bonash proposes a software system that designs a patient specific hip implant by investigating the 3D anatomical geometry of the patient’s hip joints since bone cutting and alignment have to be achieved in 3D planes in surgical operation.
Accuracy of the additively manufactured implants is important to surgeons, and the capabilities of the custom made implants affect the outcome of implant accuracy. Some of advantageous of titanium custom made implants are listed below:In order to design a highly accurate implant for individual patients, Bonash proposes a software system that designs a patient specific hip implant by investigating the 3D anatomical geometry of the patient’s hip joints since bone cutting and alignment have to be achieved in 3D planes in surgical operation.
Accuracy of the additively manufactured implants is important to surgeons, and the capabilities of the custom made implants affect the outcome of implant accuracy. Some of advantageous of titanium custom made implants are listed below:In order to design a highly accurate implant for individual patients, Bonash proposes a software system that designs a patient specific hip implant by investigating the 3D anatomical geometry of the patient’s hip joints since bone cutting and alignment have to be achieved in 3D planes in surgical operation.
Accuracy of the additively manufactured implants is important to surgeons, and the capabilities of the custom made implants affect the outcome of implant accuracy. Some of advantageous of titanium custom made implants are listed below: