When we break a bone in our body, we typically require surgery which involves inserting a metal rod into the center of the bone. My younger brother recently broke his leg and had to undergo this exact procedure to allow his leg to heal and support the bone. Seeing what my younger brother had to go through got me interested into the world of medical implants. This led me to titanium bone implants, and how 3D printing is used to make these implants.

The rise of 3D printing has revolutionised the manufacturing of implants, as now it is possible to create personalised implants and prosthetics which help improve the comfort of patients in orthopedic settings. Using 3D printing to make personalised prosthetics can provide flexibility and customisation in orthopedic environments which you don’t get with subtractive manufacturing. I think the use of 3D printing is very beneficial in the medical implant industry as being able to create implants that are personally tailored to individual patients is a development that is crucial to the improvement of implants.

Why titanium?

Titanium is used in implants because it is very biocompatible, which means it is not harmful to any living tissue. Because titanium is very biocompatible, this makes it resistant to corrosion from bodily fluids, which allows it to be more acceptable by the body. Titanium is unique in the sense that it is able to bind with bone and living tissue, which makes it well suited for orthopedic implants. This ability to physically bind with bone allows it to grow into the titanium implant as it heals (a process called osseointegration) gives titanium an edge over other materials.

How does 3D printing make titanium implants?

There are 3 main 3D printing methods which are commonly used to make titanium implants: Direct Energy Deposition, Electron Beam Melting and Selective Laser Melting.

Direct Energy Deposition (DED), is where a high energy source such as a laser is used to melt the titanium powder as it is passed through onto the substrate. The benefit of this method is that it is able to create large parts at a high deposition rate.

Electron Beam Melting involves applying an electron beam to a layer of titanium powder, which is then melted and fused with the previous layer. This method is more suited for smaller, complex parts as it is conducted at a high temperature and in a vacuum which leads to minimal stress on 3D printed parts. Selective Laser Melting, is similar to electron beam melting, but uses a laser to melt and fuse layers of titanium powder.

Future outlook of 3D printed bone implants

3D printing has made big strides in the medical implant field as it is at a stage where the potential of this technology can be increased with the improvement in machine capabilities and materials. The emergence of 3D printing can transform the field due the continuous evolution of 3D printed processes which can create innovative implants whilst reducing production costs.

My thoughts

I believe that 3D printed titanium implants can shape the medical implant industry as it is very important to ensure that patients needs are met to ensure a high standard of healthcare and I believe that with the recent advancements that have been made in 3D printing, as well as the benefits that titanium provide for the human body, that we are a step closer into improving medical prosthetics and implants.