Additive manufacturing for biomedical applications

Additive Manufacturing for Biomedical applications
Grégory Nolens & Carsten Engel
Workshop, January 23th 2014

le centre collectif de l’industrie technologique belge

Mission

Collective centre
of the technology industry
• Non profit organization
• Industry owned

“Increase the competitiveness of companies of
the Agoria sectors through technological
innovations”

130 experts & high-tech infrastructure
4,700 industrial interventions
(advice, projects, services)
•within 1,700 different companies
•whose 75% are SME’s
•24M EUR turnover

© sirris 2012 Charleroi | www.sirris.be | info@sirris.be | 23/01/2014

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Additive Manufacturing/3D Printing :
Basic Principles
Basic data :
Layer by layer manufacturing

Starting point:
3D CAD file

3D CAD File

3D STL File

Sliced File

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3D Printing – Next
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Obama said (feb. 2013): "A once-shuttered warehouse is
now a state-of-the art lab where new workers are mastering
the 3-D printing that has the potential to revolutionize the
way we make almost everything“

“We can’t wait” initiative


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Fashion effect – public machine
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Design, gadget,

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but also functional and caring


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Industrial and technical products
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Prototyping
No assembly
Personalized
Technical
Porous


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Additive Manufacturing : Basic Principles
Advantages of using AM … try something new !
• Low-cost ability to easily try out ideas generates many
innovations
• AM has seen children returning to making things. From
digital into reality.
• Testing the market with an idea with small production
• Alows inventors to realize their inventions and test
their market


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Additive Manufacturing : challenges
 Variety of materials still not vast enough
 Lack of precision on some technologies
 Machines still very pricy (industrial)

 Need of certification and qualification of materials & process
 Lack of surface quality and finishing
 Not suited for big series (automobile)


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Additive Manufacturing technologies @ Sirris
SIRRIS – European leader: Most complete machine park
• 15 engineers and technicians
• Two locations: Liège (10 p.) and Charleroi (5 p.)

Rapid Prototyping / Tooling / Manufacturing
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Stereolithography (normal & hi-res)
Paste polymerisation for ceramics and metals (Optoform)
3D Printing of plaster and metal powder
Laser sintering of polymeric powder (PA,…): P360 – P390
Objet Connex 500: bi-material
Laser sintering of metal powder (parts and mould inserts)
Electron Beam Melting (Arcam A2)
3D Printing of wax (Thermojet)
Vacuum Casting of Alu, Bronze, Zamak
Laser Cladding (EasyClad)
Selective Laser melting (MTT)
Mcor - paper
Bi-material FDM system

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The utility of Additive Manufacturing technologies
in the medical field
Next generation pre-operative manufactured implants:
• Custom implant manufacture :
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CT-Scan
CAD File of the patient is produced
Engineer + Surgeon 3D implant approved
FEM analysis (when needed)
Custom manufacturing (low cost)
Surgery
Follow up

[Sirris ADD]

[Sirris ADD]
[Sirris ADD]

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ADD capacities & competencies
Medical Additive Manufacturing Software:
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Materialise: Mimics
Materialise: 3matic
Marcam: Autofab
Able Software Corp: 3D Doctor
Medicim: Maxilim
ProEngineer
New: Lenexa: Analyze
New: Brisbane: Anatomics
(…)

[Mimics & 3-matic - Materialise]

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Additive Manufacturing in the medical field

Leading applications:
• Custom implant manufacture
(Scanning/Custom Prosthesis Design)
• Pre-surgical planning

[Arcam & Objet technology]

• Physician to physician communication
• Powerful patient presentation tool

[Z. Corp Medical Modeling Solutions]

• Medical student/resident education
[Sirris ADD]

[Z. Corp Medical Modeling Solutions]

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The utility of Rapid Prototyping / Manufacturing in
the medical field

“No matter how good our 3-D graphics are, there is
nothing like a model in your hands . . .”

• Pre-surgical planning:
• Implant pre-contouring
• Screw trajectory
• Screw selection/location
• Instrument selection
• Technique rehearsal

[Objet]

[Objet]

[Objet Connex Eden 500]
[Objet]

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Medical Field: CASE STUDIES @ SIRRIS
• Physician to physician communication
• Powerful patient presentation tool
• Medical student/resident education
[Sirris ADD]

[Sirris ADD]

[Sirris ADD]

[Sirris ADD]

[Sirris ADD]

[Sirris ADD]

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Spinal & CMF case studies in ceramic
• Porous scaffolds for Spine surgery
• In vivo testing for bone integration
• Validation production by Sirris  Tech transfer
• Field: Maxillofacial Surgery in France, production in Belgium

[Sirris ADD]

[Sirris ADD]

[Sirris ADD]

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Medical field: Industrial Case studies
Project: “In vitro testing models - arteries”

• Goals:
• To gain biomechanical know-how
• Virtual prototyping, device testing, virtual design iterations
• Diagnostic research
• Technologies involved: Connex Eden 500 bi-material 3D inkjet printing

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Surgical Cutting Templates
• UCL-St Luc (Belgium)
• UCL spin-off: VISYOS
• Polyamide cutting patient-custom cutting tools
• SLS technology + bio-coating

[VISYOS]

[VISYOS]

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Surgical Cutting Templates – reimbursement problem

Surgical guides not reimbursed, but facts are:
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1 min. in surgical theatre (estimated): 60€

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Mean of orthopedic surgery duration: 5-12h (18k-44k€)

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Surgical guide can reduce: 20-70% of the duration (TBC)

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Surgical guide cost: 50-300€

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Economy: estimated 3-30k€/surgery

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Medical Field: CASE STUDIES in the world

[Dr J. Poukens – Uhasselt, Xilloc Medical (Maastricht)]

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World’s first total mandible implant in Titanium

[UHasselt, Layerwise, Xilloc, Sirris, CamBioceramics, Orbis Medisch Centrum, Xios, KUL]

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Towards newly designed implants
Finger implant (Dr. P. Ledoux, Prof. G. Guerlement UMONS)

[Université de Mons, Faculté Polytechnique]

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The future of bio-manufacturing…not so far away!

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What’s Bioprinting
process of printing biologically relevant materials (such as cells,
tissues, and biodegradable biomaterials) that will accomplish
one or more biological functions
3D machine

cells

Bio-glue

+
Scaffolds
+ cells

Tissues/organs


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Bioprinting – an emerging technology

Bioprinting place in emerging technologies, from the Hype Cycle for Emerging
Technologies 2013- Gartner

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Market approach  interest for companies?
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Applications:

• Drug discovery & Assays
• Cell therapy + Tissue Engineering

• Bioprocess
• In vitro diagnostic & research
• Food


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Drug Discovery and Assays
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Facts: Drug Discovery and Assays
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90-95% of drugs approved on animal (mouse, rabbit, etc.), was not
for human  lot of money lost, ethic problem
Animal use: 10-100 Mio in US/year
European Comission banning: FULL on cosmetic (2013), next
pharma (?)


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•

Drug X

Applications:

• Drug screening w/o animal

& less deviations
Pharmaceutical area

Disease tissue

Treated tissue
Organovo’s targeted market

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Cell Therapy & Tissue engineering
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Facts: Tissue engineering
• Alternative to donor waiting list
• Limited available « material » resource (skin, organs, cells, …)


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Facts: Cell Therapy

Cell therapy industry market
(2008–2014).
Graph showing the estimated
CTI revenues from 2008–2014


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Facts: Cell Therapy

High potential for
Small defect repair


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Applications:

• Large defect repair


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Applications:

• Biocompatibility assays w/o animals (ISO)

Artificial skin

Irritation


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Technological approach
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Applications:

• In vitro diag and Research
• Biomarker

• Drug kinetic
• Pathogen reaction


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Biotechnolgies & Bioprocess
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Applications:

• Biomolecule production in 3D

• Machine producers


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Food & Agriculture
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Applications:

• New food process?

Focus on food player with Life
Science approach: biomaterial
( e.g. Tissue engineering)


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Bioprinting
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Where beginning R&D?


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Tissue engineering basics
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Lamarck (1744–1829): La fonction crée l’organe
(The function creates the organ).


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Lamarck (1744–1829): the function creates the organ.
daylife example: tissue reacts to device

« 2nd skin » development


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One scaffold can be enough

Tube with structure mimicking vascular matrix

Rat implantation

Cell infiltration  differentiation  scaffold disapear  tissue restorated

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Scaffolds + stem cells + growth factors = work better

Artificial kidney tissue

Artificial heart tissue
(Taylor, Minnesota, 2009)

Scaffolds come from animal washed for cells

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3D Bioprinting solutions

Personalized
scaffolds 
incubation with
stem cells
IPL, UGent, …


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Nanostructure for
fluidic, cell interaction,
scaffold,…
2PP (two photon

Nanoscribe

polymerisation)

Very small devices

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Industrial machines
Personalized
scaffolds 
incubation with
stem cells
(and cell printing)

EnvisionTech, GESIM, Regenovo (China)…


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Personalized
scaffolds +
stem cells 
incubation


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Bioprinting players in the world
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Keyplayers outside Europe

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Dr. Shinya Yamanaka (JPUS): stem cells

• Dr. Anthony Atala (US, Boston)

• Wake Forest University (US, North Carolina)
• ACES (Australia) biopen
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China


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Bioprinting players in Europe – few


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« Medical Additive Manufacturing & Rapid Prototyping »

« Sirris »

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Sirris Additive Manufacturing: Contact

Carsten ENGEL, Ir, MBA

Grégory NOLENS, PhD

Department of Additive Manufacturing

Department of Additive Manufacturing

Mail: carsten.engel@sirris.be
Mobile: +32 498 91 94 50
Skype: Carsten-Engel

Mail: gregory.nolens@sirris.be
Mobile: +32 498 91 94 75
Skype: gnolens

SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be

SIRRIS
Rue Auguste Piccard, 20
B-6041 GOSSELIES BELGIUM
http://www.sirris.be

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Additive manufacturing for biomedical applications

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