On September 19, 2018, German medical device company endocon GmbH developed a 3D printed surgical tool with the help of GE’s Additive Concept direct metal laser melting (DMLM) technology. Medical-grade devices are designed to improve and simplify the removal of hip implants with the choice of 15 additive-made stainless steel blades.
With this technology, Endocon can save manufacturing time and money while reducing the risk of complications.
endocon’s endoCupcut device with 3D printing blade
Simplified surgical removal of hip implants
The implantation of the acetabular cup is relatively conventional hip replacement surgery. However, their removal is a much more complicated process. Usually, surgeons use a chisel to remove the implanted acetabular cup, posing a risk to the patient’s bones and soft tissues.
Endocon’s endoCupcut product was created as an alternative to the acetabular cup removal tool. The endoCupcut tool has 15 replaceable blades ranging in size from 44mm to 72mm, allowing more precise cutting along the edge of the acetabular cup for loosening and extraction.
These blades are manufactured on Concept Laser Mlab.
3D printing blade
17-4 PH stainless steel powder was used as the material for making the endoCupcut blade. Depending on its size and orientation, 2 to 6 blades can be 3D printed at any time on a Mlab 90 mm x 90 mm construction board. Including data preparation, 3D printing, high-quality surface treatment, hardening and sandblasting, Weber-KP takes about three weeks to provide a complete set of endoCupcut blades.
Before using additive manufacturing, these blades were cast into metal from a mold. In addition to having good reputation, corrosion and consistency issues, the production cycle of casting blades can be as long as three and a half months.
In terms of biocompatibility, 3D printed blades made the results of acetabular cup replacement more consistent, and the rejection rate was reduced from 30% to less than 3%.
The post-processing and 3D printed parts of the endoCupcut device are still connected to the build board
Klaus Notarbartolo, general manager of endocon, commented, “We are also able to reduce the cost per blade by about 40 to 45 percent. This means we can save costs for our customers. When you compare it with reducing product development time, more When combined with high efficiency and lower scrap rates, the business case for additive manufacturing really becomes attractive. “
The endoCupcut device adds GE Additive’s growing list of medical applications. In June 2018, Sutrue, a UK-based medical technology company, introduced an automatic suture device 3D printed by Concept Laser. GE additive ARCAM Q10 Plus has been approved by the FDA for the manufacture of orthopedic implants.