How implant manufacturers use Additive Manufacturing to reduce production costs and increase profits

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Bertina Hopkins
8 years ago
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1 Electron Beam Melted (EBM ) Ti-based medical implants or How implant manufacturers use to reduce production costs and increase profits

2 Arcam Swedish innovation from the beginning of the 1990 s Arcam AB incorporated 1997 Listed on Nordic Growth Market Main owner (25%) Industrifonden (Industrial capital trust) Turnover 10.1 M (2010) First EBM system delivered in 2003 About 70 systems installed worldwide 50 people, in Sweden, the U.S., Italy and China Sales partners in Europe and Asia

4 Electron Beam Melting (EBM ) A high energy beam (up to W) is generated in the electron beam gun The beam melts each layer of metal powder to the desired geometry The high beam power gives high build rate (up to 80 cm 3 /h) and productivity Extremely fast beam translation with no moving parts Vacuum process eliminates impurities and yields excellent material properties High process temperature (700 ºC for titanium) gives low residual stress > no need for heat treatment Low operating costs

power gives high build rate (up to 80 cm 3 /h) and productivity Extremely fast beam translation with no moving parts Vacuum

5 Overview Applications Medical Implants Aerospace Arcam Products Materials Medical Implants

6 EBM - Core Benefits Freedom in design Excellent material properties Cost-efficient production And, for implant manufacturing

7 Production Technology for Trabecular Structures Design your trademark trabecular structure in CAD Optimize for osseointegration Competitive manufacturing costs Pore geometry (no limitation) Pore size (down to ~400 µm) Porosity (up to ~85%) EBM production cost, typical: < 2 / cm3 trabecular structure 7

manufacturing costs 2011-12-13 Pore geometry (no limitation) Pore size (down

8 Bio-Compatibility Pictures of bone growing into EBM-manufactured titanium implants with Trabecular Structures Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials, University of Gothenburg

Structures Courtesy of Professor Peter Thomsen, MD,

9 Implant Categories Acetabular cups Revision cups Augments Femoral stems CMF Spine Shoulders Triflanges Tibial trays Femoral knees In production with EBM

10 Production Technology for Production Benefits Single-step production of solid and porous sections, with structural continuity between them All-porous implants possible (augments, wedges, ) No secondary high temperature process to apply the porous structure that could cause grain growth High process temperature gives low residual stress, and no need for heat treatment after the build

secondary high temperature process to apply the porous structure that could cause grain growth High

11 Cost Savings with EBM The additional cost for applying a porous coating on an acetabular cup can be anything from 30 to 60 per cup With EBM you produce the cups with an integrated porous structure, which eliminates this cost When producing acetabular cups from bar, 60-70% of the stock material is typically machined away With EBM you only use the material needed to produce the cups. The remaining powder is recycled and reused

cost When producing acetabular cups from bar, 60-70% of the stock material is typically machined away With EBM

12 EBM Production Cost, typical of Ti6Al4V acetabular cups with integrated trabecular structures Cup Weight Build Batches per Cups per Production size cup, build time / batch week batch cost / cup (g) (h) ( ) Includes costs for EBM system, material, Support & Maintenance agreement and operator

95 10 14 12 54 52 104 10 14 12 56 54 113 11 14 10 65 56 123 11 13 10 69 58 133 11 13 9 76 60 143 11 13 9 78 62 154 12 12 9 83 64

13 CE-certified Implants since 2007 CE-certified acetabular cups with integrated, engineered Trabecular Structures since 2007 Implants with FDA clearance since 2010 > 40,000 cups manufactured > 20,000 cups implanted Adler Ortho, IT 2007 Lima-Lto, IT 2007 Exactech, US

FDA clearance since 2010 > 40,000 cups manufactured > 20,000 cups

14 Summary EBM lets you design and produce unique trademark Trabecular Structures with minimum investment EBM offers a uniquesingle-step production method for solid and porous implants EBM provides structural continuity between solid and porous sections, and requires no heat treatment EBM is a proven and cost-efficient technology, with thousands of implanted CE-approved products

provides structural continuity between solid and porous sections, and requires no heat treatment

15 Overview Applications Medical Implants Aerospace Arcam Products Materials Aerospace

16 Turbine Blades Material: γ-tial Size: 8 x 12 x 325 mm Weight: 0,5 kg Build time: 7 hours / blade For stages 6 and 7 in the low pressure turbine in General Electric s GEnx aero engine, where the TiAl (~4 g/cm3) replaces blades made in heavier (>8 g/cm3) nickel-based superalloys

turbine in General Electric s GEnx aero engine, where the TiAl (~4

17 Contact Thank you for your attention! Arcam AB Krokslätts Fabriker 27A SE Mölndal, Sweden Phone: Web site: Arcam - Manufacturing Revolutionized

Sweden Phone: +46 31 710 32 00 Web site: http://www.

EBM Inside. Additive Manufacturing of orthopedic implants

EBM Inside. Additive Manufacturing of orthopedic implants EBM Inside Arcam provides a cost-efficient Additive Manufacturing solution for production of implants. Arcam s EBM technology is used for production of FDA-cleared and CE-certified orthopedic implants.