World’s first Titanium chest implant. Credit: HeroX
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.
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.
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.
Prosthetics are substitutes for missing limbs in the body, in particular arms and legs, but also bones, heart and arteries. There are 30 million people in need of replacement limbs, but the main challenge that people face is that prosthetics are very expensive.
According to this report, the average cost for a single prosthetic limb is around $4,500 USD and can go as high as $50,000 USD. For people in low income countries, this can be unattainable and for people in high income countries, this can be expensive. As a result, I started to think about what solutions are out there that could potentially help this cause. After some research, I came across the field of 3D printed prosthetics, which caught my eye.
What exactly are 3D printed prosthetics?
Essentially, 3D printed prosthetics involves using additive manufacturing methods such as 3D printing to create artificial limbs instead of manually manufacturing them. 3D printed prosthetics are composed mainly of plastic, just like traditional prosthetics, but can also use materials such as acrylonitrile butadiene styrene, or simply ABS, plastics, as well as bridge nylon for a stronger material.
There are 4 main types of prosthetics: transradial, transhumeral, transtibial, and transfemoral. The first 2 types are implants above and below the arm, whilst the last 2 types are implants above and below the knee. Additive manufacturing enables the fast production of these implants.
How do 3D printed prosthetics work?
3D printed prosthetics offer a more streamlined approach to the manufacturing process of prosthetics in comparison to the traditional method. There are 4 steps to this approach, with the first step being 3D scanning. This involves using medical imaging methods such as X-rays and Computerised Tomography (CT) scans to collect images of the patients broken limb.
The next step involves the images being modelled by prosthetists to create and design the required device. This is heavily influenced by the level of detail the computer software provide. The third step is the 3D printing itself, which print layers of the material to create a bonded object. This method prints lots of complex structures in a short period of time. Finally, the device made is fitted onto the patient, where the device made is designed to match the patients anatomy.
This video details the company Unlimited Tomorrow, who create prosthetic arms using 3D printing which has led to the production of their True Limb device.
Freethink/YouTube
Benefits and Challenges of 3D printed prosthetics
The benefits that 3D printed prosthetics provide are the reductions in the manufacturing time and costs of the prosthetics. Prosthetics produced by traditional methods often involve stringent procedures, whereas, 3D printed prosthetics offer a more step by step method which is more streamlined.
The average cost of a prosthetic arm costs around $2,000 USD, and the patient may have to wait for the prosthetic to come. Prosthetics 3D printing is more affordable in comparison, with the cost of a 3D printed prosthetic costing around $395 USD.
One challenge that 3D printed prosthetics face is in regards to material strength and durability. 3D printed prosthetics can be created by thin layers of hot plastic, which can be broken easily. Some prosthetics also incorporate materials like silicone, which can be challenging due to the limited availability of printers that can handle these materials.
The rise of 3D printing can potentially create a bright future for prosthetics thanks to the technological advances made in prosthetics design, as well as the cost efficiency, rapid production times and flexible design.
Recently, I stumbled across a new idea, or shall I say, a new invention from none other than Elon Musk. As we all know, Musk has been at the forefront of revolutionising the technological world with his ideas and innovations, culminating in his successes achieved with Tesla and SpaceX. So it comes as no surprise that he’s back with another idea, but this time involving the human brain. This new innovation is called Neuralink. You may be curious to know what it actually is. Neualink is Musk’s new neurotechnology company which aims to create generalised computer interfaces which can be implanted into the brain to be able to unlock the human potential and restore autonomy by enabling wireless communication across the world. Now this sounds quite innovative and would definitely change the landscape of the world, but is there more to this that we should be skeptical about?
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