As the population continues to age, the number of necessary hip replacements rise, which means we’re seeing more 3D printed hip implants and hip cups. Implanting a hip cup is fairly straightforward these days, but removing one, for reasons ranging from abrasion and infection to loosening, is another story. Surgeons typically have to use a hammer and chisel for this, which can damage tissue and bone and make it hard to reinsert a new implant.
“We’ve also been able to reduce the cost per blade by around forty to forty-five percent. That means cost savings for us and in turn for our customers,” said Klaus Notarbartolo, the General Manager at Endocon. “When you combine that with a reduction in product development time, higher efficiency and lower rejection rates, then the business case for additive really becomes attractive.”
Typically, traditional casting is used to manufacture cutting blades, but for an end product that comes in a variety of shapes and sizes, it could take up to three and a half months to produce a single batch of blades. Casted blades can also have a rejection rate of about 30% due to issues like non-repeatable quality, corrosion, and consistent hardness.
The 3D printed blades for the endoCupcut, which had only minimal changes from the original model, can be available in just three weeks, including post-processing. The device now has a rejection rate of less than 3%, can achieve consistent outcomes, and the 3D printed blades show excellent corrosion resistance. Rather than cracking after 600 N, the blades show a plastic deformation after applying 1,8 kN, and their hardness level has improved to 42+-2 HRC, compared to 32 HRC.
“Endocon’s ability to solve multiple challenges using additive is impressive example of how it can have a positive impact for smaller companies targeting the orthopedic industry,” said Stephan Zeidler, Business Development Manager Medical for GE Additive. “What started with the need for a reduced time-to-market in terms of product development and flexible production of various shapes and sizes has resulted in a smart, innovative medical product that enhances patient outcomes.
“Moving the entire production process from casting to additive manufacturing was a logical step and that shift continues to provide inspiration for future projects.”
Using DMLM technology to 3D print the blades has improved their mechanical properties, and also ensures high density and accuracy. By using stronger, harder, and more reliable blades on the endoCupcut, the device performs better for the surgeon in the operating room, and also makes things safer for the patient by lowering the risk of breakage and splinters being embedded in their tissue. Using this device, surgery time has been decreased from 30 minutes to just three, and its precise cutting method preserves the highest possible amount of bone substance, which “supports an accelerated healing process for the patient.”
Other benefits of fabricating the endoCupcut blades with DMLM 3D printing include:
- High-fitting accuracy of blades through modular system of ball-shaped heads
- Perfect fitting of ball-shaped heads in a 38-60 mm width
- Reusable for multiple operations
- Wear-resistant and easy to sterilize
Lowering surgical risk saves hospitals money and time, and the world is definitely taking notice of Endocon’s innovative work. The endoCupcut is already being used by several medical professionals around Germany, and the company itself is a finalist in the TCT Awards next week.
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[Images provided by GE Additive]