Material Advantage: How Additive Manufacturing Can Revolutionize Orthopedics

Additive manufacturing, popularly known as 3D printing, has captured the world’s imagination in recent years. As the technology becomes affordable and scalable, 3D printing is increasingly accessible for individuals and businesses. In orthopedics, this is leading to revolutionizing innovations to both surgical tools and orthopedic implants. Speed and efficiency in manufacturing are experiencing a sea-change with additive manufacturing, and the potential for customization in local settings makes additive manufacturing stand out for orthopedic settings. This is a material advantage for early adopters of this new technology.

Surgical Tools On Demand
3D printing is leading a revolution in the customization of surgical instruments. Traditionally, standard designs have dominated the market, meaning surgical instruments have been (relatively) blunt tools, designed to meet multiple purposes. Additive manufacturing presents the opportunity for surgical materials to be produced on demand and customized according to the surgeon’s needs, the procedure, or even unique physiological factors about the patient herself. With 3D printers becoming affordable and accessible, care units will increasingly have access to additive manufacturing capabilities—this will enable materials to be produced at the point of care to specific local requirements.

“Selective Laser Sintering (SLS) is the reliable 3D printing process for the building of complex objects for use in orthopedic environments,” said Jens Saunders, orthopedics expert at Essayroo and OXEssays. “SLS printers can produce several components at once, meaning multiple tools can be acquired to suit specific needs.” The use of polymers in this process results in lightweight and ergonomic tools that surgeons find comfortable and easy to use. This facilitates better care in an orthopedic setting as surgeons become more effective, and the customization of these tools means that they are perfectly suited for the procedure at hand.

High Volume Production
As well as the fine-tuned customization, providing tools that perfectly fit the varying factors of surgeon, procedure, and patient, additive manufacturing can also provide tools at short notice thanks to some of the unique manufacturing abilities of SLS technology. In some circumstances, such as orthopedic trials, medium to high volume of instruments will be required. Since SLS printing enables multiple components to be produced simultaneously, instruments with a high degree of complexity can be built with speed and efficiency in mind. Hospitals and other orthopedic environments can greatly benefit from having on-hand additive manufacturing facilities to ensure the demand for instruments will always be met.

Traditional materials such as titanium and cobalt chrome are still prevalent in orthopedic tools, and the relatively lower cost of these materials has drawn manufacturers in over the years. However, conventional manufacturing processes that utilize these materials and neglect the role of additive manufacturing produce a significant amount of waste. Efficient use of metals in manufacturing is challenging because of the necessity to make cuts, leading to scrap. With additive manufacturing and SLS technology, waste is brought to a minimum as the polymers used in these processes are highly malleable when compared to titanium, for example. When engaged in higher volume production, speed and efficiency are additional benefits of additive manufacturing.

Orthopedic Implants
The potential for the additive manufacturing of orthopedic tools is apparent. Highly specific tools customized for surgeon or patient can be made for unique functions, and tools created with speed and efficiency can be created in bulk at the other end of the spectrum. A third application of additive manufacturing in orthopedic settings is the production of orthopedic implants.

“Additive manufacturing allows new materials to be used in the production of orthopedic implants,” said Sheila Mackay, medical writer at Paperfellows and State Of Writing. “This means that thermoplastics such as polyetheretherketone (PEEK) can be leveraged for its physiological benefits as well as its manufacturing benefits.”

PEEK shares characteristics with bones in weight and density, meaning it can be seamlessly integrated into the body. Polylactic acid (PLA) is another such polymer that can be produced through a process of additive manufacturing to replicate the titanium screws used in certain surgeries. While titanium screws ultimately require further operations (and an additional risk of complications) to remove, PLA materials are bioabsorbable meaning no further operations are required.

The Future Of Orthopedics
Additive manufacturing is perfectly adaptable for orthopedic settings and brings many benefits. Customization of tools and speed of production offer revolutionary advantages over conventional manufacturing techniques. Further, the materials that can be used for additive manufacturing have many benefits simply not available in traditional materials. The future of orthopedics is in additive manufacturing.