3D Printed Medical Devices: The Ultimate Guide

3D printing is the process of manufacturing 3D components used in different applications. The healthcare sector requires manufacturing 3D printed medical devices due to the efficiency and high quality offered by the process. If you want to learn about the overall process involved, you can read this guide below.

What is Medical 3D Printing?

Medical 3D printing involves creating components used in the medical industry that are three-dimensional. These objects are manufactured layer by layer, and the materials used in the medical 3D printing are all medical-grade materials.

Custom products like implants, medical devices, and anatomical models are manufactured. The process allows manufacturing components that are customized and precise. These components can be used in various fields like dentistry, surgery, and prosthetics.

Advantages of 3D Printed Medical Devices

The benefits of opting for 3D printing for medical devices are the following:

Custom Medical Components

3D printing offers the creation of personalized medical components that are manufactured for individual patients. This usually consists of manufacturing 3D printed prosthetics and implants. Since these are designed for individual patients, they are a perfect fit for the patients.

Rapid Prototyping

3D printing allows for quick design creations and hence can be used for rapid prototyping of medical devices. The method helps accelerate the process of development, and the manufacturers can test the devices before mass production.

Complex Medical Components

The traditional methods of manufacturing medical devices usually struggle with producing the components, which are complex in terms of design. 3D printing helps create complex and detailed designs. Hence, specialized components can easily be manufactured.

Cost-Efficient Manufacturing

3D printing is suitable for medical devices that are highly customized or are produced in small batches compared to traditional manufacturing. Such medical devices are cost-effective and prove to be an economical choice for production runs which are limited as no expensive tooling and molds are needed.

Less Wastage

3D printing is a manufacturing process in which only the needed materials are used due to it being an additive manufacturing process. Hence, the waste is reduced compared to the subtractive manufacturing processes.

Limitations of 3D Printed Medical Devices

Along with the advantages, there are some downsides to 3D printed medical devices. Some of these are given below.

• Medical devices are meant to meet the strict regulatory requirements. The nature of medical devices is very sensitive, and the approval process for these devices is also time-consuming and complex.
• There is a wide range of materials available for 3D printing, but not every material is suitable for medical applications. Some of them may lack biocompatibility as medical devices require durability and long-term usage.
• 3D printing usually ends up creating a surface that is rough. Many medical devices need smooth surfaces like implants and other surgical tools.
• The mechanical properties of 3D printed components vary based on the method of printing and the type of material used. Not every type of device will have the same wear resistance that a traditional manufacturing method will need.

The Process of 3D Printing Medical Devices

Some of the processes opted for 3D printing medical devices are the following:

SLA

SLA 3D printing uses a laser which makes the resin in liquid form in the hard plastic after curing. SLA is one of the most popular methods of manufacturing medical devices due to the material versatility and high precision it offers.

The medical components manufactured by SLA are highly accurate and offer a smooth surface finish. Hence, medical components that need tight tolerance and a smooth finish may opt for this process.

SLS

SLS is a high-power laser that helps fuse the particles of polymer powders during the printing processes and create the desired medical component. The SLS is a very effective process opted for manufacturing medical components that are complex.

The process doesn't need any support structure and can be opted for components that have complex internal features and need thin walls and undercuts. SLS works well with nylon and helps produce medical devices that can be sterilized and are biocompatible.

FDM

FDM is a method of 3D printing that works by melting the thermoplastic filament and extruding it. The printer nozzle tends to deposit layer after layer the components to be manufactured.

FDM is compatible with a wide range of materials that are biocompatible and suitable for use in the medical industry.

Medical-Grade 3D Printed Materials

The materials compatible with medical applications using 3D printing may include the following:

Polylactic Acid (PLA)

PLA is a very popular plastic that is used in FDM 3D printing. It is low-cost and easy to work with, offering biodegradability. The PLA and 3D printing work in manufacturing medical devices like fixation pins, plates, bone scaffolds, and screws.

Acrylonitrile Butadiene Styrene (ABS)

ABS is a strong and light material that can be melted and turned into a liquid for 3D printing. Upon solidification, it creates high-quality, lightweight medical devices. These components made using 3D printed ABS are used as prosthetics, orthopedic corsets, and in surgical operations.

Polyetheretherketone (PEEK)

PEEK is a highly chemical-resistant material that offers excellent mechanical properties. It is used instead of metal in many applications which include customized medical devices like implants.

Titanium

Titanium is used in the medical sector for manufacturing 3D printed surgical instruments and joint replacements. Implants like spine, knee, and joint are manufactured using 3D printing and titanium due to its biocompatibility and mechanical properties.

Polyethylene Glycol (PEG)

PEG has biochemical properties, which makes it suitable for the medical industry. Hence, the 3D printed PEG components are used in manufacturing casual tissues, bones, and cartilage.

Medical Applications for 3D Printing

Some of the medical applications for 3D printing may include the following:

Prosthetics and Bone Implants

3D printing helps create custom bone implants that match the anatomy of patients. Spinal implants and other joints are manufactured using 3D printing. Custom prosthetics for limbs can be made using 3D printing, which allows affordability and precise fit to the patient.

Surgical Tools

Surgical tools that are used in complex surgeries like joint replacements which require precision are manufactured using 3D printing and offer high accuracy. Custom surgical instruments can be used in unique procedures and enhance the effectiveness of surgeries.

Dental Applications

3D printing is commonly used in dentistry applications. It helps create custom crowns, bridges, and dental implants according to the fitting of the patient’s mouth. Apart from this, other devices like retainers and aligners are also manufactured using 3D printing.

Hearing Aids

Hearing aids are very crucial for various patients. These custom hearing aids need to be designed according to the perfect fit and shape of the patient’s ear canal. They offer great performance and can be manufactured with 3D printing.

Conclusion

3D printing in medical devices is very common due to its flexibility and affordability. Low-volume customized components for individual patients can also be manufactured through this process. If you are looking for precise and high-quality 3D printed medical devices for your applications, you can get in touch with DEK.

FAQs

What is the process of 3D printing medical devices?

The workflow of 3D printing consists of the stages from the creation of ideas to the final component manufacturing through 3D printers with the help of additive manufacturing.

What are the unique capabilities of 3D printed medical devices?

3D printing medical devices allow for personalized manufacturing of these devices based on every single patient’s specifications.