Project investigates 3D printing's affect on medical devices

German-American chemical company Linde has launched a new project looking into how atmospheric conditions in the 3D printing process can be best optimised to make viable orthopaedic medical devices.

Done in collaboration with 3D Medlab, an additive manufacturer in the medical sector, the project is the first of its kind and represents a milestone within the industry.

The research primarily focuses on the development of latticed components mimicking body parts, with the intent on developing structures that can better assimilate to the patient’s bone and tissue structure, allowing for faster healing times and fewer complications.

If the process can be refined and optimised, the use of additive body parts can be repeated on an industrial-scale with very few risks associated and require less post-print finishing.

Atmospheric gases play a vital role in the process, but the atmospheric conditions these chemicals find themselves in must be perfect and reproducible. If the process is inconsistent, the quality of the end product will suffer greatly.

Additionally, fumes may remain on the medical devices in post-production, requiring cleaning and careful handling before application.

Many extraneous scenarios may effect on the end product. For example, even a small change in oxygen levels can impair the mechanical or chemical properties of metals sensitive to oxygen – such as titanium – which can affect the composition of the device.

Pierre Forêt, senior expert manufacturing, Linde, said: “We are proud to be collaborating with 3D Medlab on this important and forward-looking project. As a customer at the forefront of medical device manufacturing, anything less than optimal product outcomes is critically important to avoid, so it is testament to our gases expertise and know-how that we have been selected to partner in this endeavour.”

The atmospheric trials involve a mixture of helium and argon designed specifically by Linde for this occasion, as well as special technology engineered to accurately measure the oxygen levels during production. Along with the new gas mixture, this should give the chemical company precise and granular control over the oxygen concentration and humidity levels in the print chamber.

Gaël Volpi, CEO, 3D Medlab, said: “Our experience with Linde shows that they are as committed to the same high standards of precision and excellence in additive manufacturing that we are. Full regulatory compliance is a fundamental cornerstone in our engineering and design process and our customers trust us to ensure all proper measures and controls are in place.”

Linde’s association with 3D Medlab began through the supply of its ADDvance powder cabinet, designed to retain the quality of valuable, sensitive metal powders used in the additive manufacturing process by protecting them from exposure.

While the current collaboration focuses on lattice structures of a particular titanium alloy – Ti-6AI-4V, future efforts will include other metals, such as nickel-titanium (nitinol) given its excellent shape memory and elasticity, making it an ideal candidate for orthopaedic treatment.

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