3D printing is transforming healthcare by enabling customized medicine, improving surgical techniques, and increasing efficiency in the operating room. The technology is being applied in various specialties, including orthopaedics, paediatrics, radiology, oncology, and cardiothoracic and vascular surgery.
Impact on Clinical Care:
Implants and Prosthetics 3D printing allows for the creation of personalized prosthetics and implants, which can improve fit and function for patients. The FDA has approved 3D technology for developing dental implants and has the potential to transform the way surgeons treat patients with musculoskeletal injuries.
Anatomical Models 3D printers produce accurate and detailed anatomical models that help surgeons prepare for complex procedures, improve outcomes, and reduce surgery time. Medical professionals can repeatedly practice on scanned and printed 3D models of internal organs.
Medical Equipment 3D printing facilitates the rapid development of medical devices like forceps, clamps, and retractors, which helps reduce supply chain issues.
Drug Delivery Swiss researchers are developing micro-robots using 3D printing to transport drugs within the human body, improving the effectiveness of minimally invasive surgery, targeted drug delivery, remote sensing, and single-cell manipulation.
Neural Regeneration Researchers at Michigan Tech are using 3D printing to regenerate neural tissue by constructing a matrix to re-implant cells back into the body. This technology can help with neural tissue regeneration in spinal cord injury patients.
Microneedles High-resolution 3D printing can create microneedles with complex geometries, enabling more effective vaccinations. A 3D-printed microneedle has been shown to achieve a significantly greater immune response compared to traditional vaccines.
Future Potential:
New Materials Future implants could be made with high-performance polymers, and healthcare institutions can use 3D printing for rapid prototyping, avoiding expensive tools.
Biodegradable Products Medical innovators are working on 3D-printed medical products that can dissolve in the body after use, such as stents that disappear over time without needing surgical removal. This is particularly useful in pediatric care.
Bioprinting involves using 3D printing to create artificial body parts from materials that incorporate living cells, potentially leading to the on-demand production of living tissues, bones, and organs.
Microfluidics 3D printing is used to create microfluidic devices with built-in heating elements for drug development and diagnostic applications, such as at-home COVID-19 test kits.
Spending on 3D printing is expected to reach $20 billion by 2025, which is nearly three times as much as in 2017. This increase is partly due to the needs of an aging population. The 3D printing healthcare market increased dramatically during the COVID-19 pandemic as hospitals used the technology for PPE and medical devices. In 2019, 113 hospitals had centralized 3D facilities, compared to only three in 2010.
How does a 3D printer work ?
3D printers create three-dimensional objects from a digital file through a process called additive manufacturing. Unlike traditional methods of manufacturing, which often involve cutting away material, 3D printing builds up an object layer by layer. This allows for the creation of complex shapes and designs with precision.
The 3D Printing Process:
Digital Design: The process begins with a digital 3D model, which is designed using Computer-Aided Design (CAD) software or created from a 3D scan.
Slicing: The digital model is then “sliced” into very thin layers using specialized 3D printing software. This slicing process divides the model into a series of 2D cross-sections, which the printer will use as a guide for building the object.
Material Selection: Depending on the 3D printer, different materials can be used, including plastics, metal powders, liquid resins, carbon fiber and more. The material is chosen based on the project requirements.
Layer-by-Layer Construction: The 3D printer then begins constructing the object one layer at a time. The specific method of building each layer depends on the type of 3D printing technology being used. Some 3D printers melt plastic or fuse metal powder with a laser. Others may harden liquid resin with light.
Finishing Touches: After the object is printed, it may require post-processing This can include washing, removing support structures, sanding, and coating.
Different 3D Printing Technologies:
Fused Deposition Modeling (FDM): An FDM printer builds a 3D model by repeatedly printing over the same area, depositing layers of molten plastic and fusing them together.
Stereolithography (SLA): SLA uses light and photosensitive polymers6. A resin-filled blade sweeps across the cross section of the part, re-coating it with fresh material. On this new liquid surface, the subsequent layer pattern is traced, joining the previous layer.
Digital Light Processing (DLP): Similar to SLA, DLP uses light to print objects but utilizes light sources like arc lamps, making it relatively quick compared to other 3D printing technologies.
Material Jetting: Material jetting applies material in droplets through a small diameter nozzle and is hardened by UV light.
Key Components of a 3D Printer:
Extruder: The extruder feeds the material and maintains the correct temperature for melting and deposition. It pushes the material through a heated nozzle, where it melts before being deposited layer by layer.
Hotend: The hotend is where the material is melted and deposited. It consists of a heating block, a nozzle, and a thermistor to control temperature and maintain a consistent temperature for smooth extrusion.
Motherboard: The motherboard interprets the digital instructions and controls the movements of the printing head. It manages the precise movements of motors and regulates the temperature for heated elements.
3D printers have revolutionized manufacturing, allowing for faster prototyping, customized products, and complex designs. They are used across various industries, including manufacturing, automotive, aerospace, healthcare, and more.
What are the latest advancements in 3D printed implants ?
3D printing is revolutionizing the landscape of medical implants through customization, complex geometries, and accelerated product development.
Key advancements:
Customization 3D printing enables the creation of patient-specific implants based on their unique anatomy, ensuring a precise fit and reducing the risk of complications.
Complex Geometries Implants with intricate and complex geometries that mimic the natural anatomy of bones and joints can be produced using 3D printing, improving implant functionality and integration with existing tissues. Tiny holes can also be created to encourage blood vessel in-growth on a spine implant.
Biocompatible Materials The range of materials available for 3D printing is expanding, including biocompatible, bioresorbable, and composite materials that closely mimic the mechanical properties of natural tissues. Examples of biocompatible materials include PEEK, titanium, and nylon.
Accelerated Product Development 3D printing facilitates rapid prototyping, allowing for efficient exploration of novel implant concepts and faster design cycles. The technology offers the capability to quickly create and test new geometries, and move to production immediately after design finalization.
Bioabsorbable Implants 3D printing allows for the creation of bioabsorbable implants that provide temporary support before gradually dissolving in the body, eliminating the need for a second surgery to remove the implant.
Enhanced Ankle Replacement Surgery 3D printed implants, made from synthetic materials like hydroxyapatite, mimic natural bone structure and facilitate osseointegration, ensuring long-term durability while reducing the risk of complications post-operation. These implants preserve joint movement and alleviate pain, unlike traditional ankle fusions and prosthetics.
Customized Microporous Bones Patient-specific bone implants based on CT/MRI scans can be 3D printed with a uniquely bone-like internal architecture containing micro- and macro porosities.
3D Printing with Nitinol The ability to 3D print with nitinol, a shape memory alloy, could enable more sizes and configurations of stents to be made easily.
Collaboration AddUp Solutions and Anatomic Implants are collaborating on the first 3D printed toe joint replacement.
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