INDUSTRY REPORT
Materials for medical applications Hip cup printed in titanium with porous surface for better bone in-growth ( image : @ EOS .)
Advanced metallurgical materials can be engineered , for example , in a range of high-performance alloys that deliver excellent strengthto-weight ratios , biocompatibility and corrosion resistance for medical applications . These include , for example : -
■ Small-diameter precision tubes for heart valves ; cardiac rhythm management ; vascular stents ; trauma and orthopaedic implants ; surgical instruments and spinal cages .
■ Precision strip for implantable devices such as pacemaker and neurostimulator enclosures ; cranial mesh and spinal cages ; coronary and vascular stents and spring clips for header assemblies .
■ Ultra-thin foil for strain gauges ; resistance heaters ; capacitor cathodes ; stents and spring connectors for medical diagnostics ; pressure sensing diaphragms and PCB substrates .
■ Shaped wire for orthodontic brackets , toothbrush staples and MRI channel wire .
■ Sintered porous filter powders for specialty filtration components in ventilator units .
Metal products are used , for example , by the metalforming companies that make the hermetic implantable shields and cans for pacemaker , drug-infusion pump and electronic implant manufacturers . Typically metal , rather than plastic or other material , is chosen for applications that require the highest degree of strength and durability , especially when used for tools or as replacement joints which are subject to a lot of mechanical stress . Aside from purely mechanical performance , metals used in a healthcare environment must meet specific criteria that most other products do not . For example , they may need to be non-toxic in the presence of human tissue or fluids . Or , they might have to resist chemicals such as detergents and alcohols which are used for cleaning . Metal used for implants must be non-magnetic and non-corrosive , in addition to being non-toxic .
Metals used in global medical markets include titanium ; stainless steel ; platinum ; tantalum ; cobalt / chrome and Nitinol . Platinum ' s biocompatibility makes it suitable for temporary and permanent implantation in the body , a quality which is exploited in a variety of treatments . Although rarely used in medical implants , copper has outstanding antiviral and antibacterial properties and is ideal material for surfaces that are constantly being touched ( such as door handles , bed rails and switches ).
“ While seldom used in direct contact with the body , aluminium is very commonly employed for various types of support equipment that must be light , strong and corrosion-resistant . Examples include bed frames , wheelchairs , walking sticks , orthopaedic supports and IV stands . Since
3D illustration of stent angioplasty ( image : Shutterstock . com .) raw aluminium can tarnish or oxidise very easily , aluminium parts are typically painted or anodized for durability ,” commented medical manufacturing specialist , Star Rapid
The requirements for materials , production quality and process documentation are high , making for a demanding environment for production technology and process planning . To enter the marketplace , medical devices must comply with pre-defined product lifecycle parameters intended to maximise patient safety and ensure the highest quality standards .
Pricing and margin pressure from reimbursement and purchasing practices are further driving companies to seek new ways to become more efficient , speed innovation and decrease costs . Manufacturers must now embrace digitalisation to upgrade process capability , manage capacity , reduce cost and help shift their focus from managing compliance and risk to agility and product quality .
Additive manufacturing for the medical sector
While keeping an eye on costs , manufacturers need to convince their customers by improving the customisation of new products . At the same time , they must adapt quickly to market fluctuations to survive into the future . Additive manufacturing , also known as industrial 3D printing , is an extra business strategy that can help to tackle these challenges . Combining additive manufacturing with traditional manufacturing could solve many of the market ’ s demands .
“ For laboratory equipment and medical imaging systems ( also known as imaging diagnostics e . g . CT , MRT or X-ray equipment ), additive manufacturing is a production technology that offers new opportunities to optimise both the product and the manufacturing costs ,” commented manufacturer , EOS .
Many medical devices and parts for laboratory equipment are complex niche products that are only produced in small batches . Conventional production often requires expensive tools whose cost then needs to be added to the products . In contrast , additive manufacturing works without any tools , enabling parts to be manufactured in smaller batches ( right down to a batch size of one ).
The production process is based on the CAD data of the parts . This technology provides freedom of design , as well as the option to integrate functionality directly into the part . The results include shorter time-to-market and a wide range of opportunities for product optimisation . Industrial 3D printing offers customisation opportunities for needs-based production simply by adapting the CAD data .
“ Highly complex , individual geometries can be implemented with the 3D printing process – including structures that would not be possible with conventional manufacturing ,” concluded EOS . n