ADDITIVE MANUFACTURING
Example of a cranial implant produced using VESTAKEEP i4 3DF PEEK by Evonik on 3D Systems’ EXT 220 MED extrusion platform
CASE STUDY: a successful cranioplasty using 3D printing tech
Rainer Trummer from Salzburg, Austria, embodies the transformative impact of 3D printing in medicine. Born with a skull anomaly, Trummer faced prohibitive costs and technological limitations hindering corrective surgery. However, Salzburg University Hospital leveraged additive manufacturing, utilising 3D Systems’ point-of-care printing technology, to create
or particulates between the layers that are printed – that is a major advantage of our machine,” Leonhardt says. Moreover, depending on the size of the implant, the printer can print an implant in up to four hours, with capabilities to print a smaller implant within an hour, he adds.
ENDLESS OPPORTUNITIES Leonhardt states that the company sees growing interest in the technology from hospitals directly. To date, the solution provided by 3D Systems has been used to enable nearly 40 successful cranioplasties in Switzerland at University Hospital Basel, in Austria at Salzburg
a custom skull implant for Trummer – this marked the fi rst use of the hospital’s own EXT 220 MED 3D printer for such a purpose. The implant development
involved using an expander. And over several months, the expander was fi lled with a total of 260ml of saline solution over one and a half years to stretch the scalp for full implant coverage. The surgical procedure entailed
expander removal, fi xation with mini plates and screws, and wound care, culminating in the formation of a natural tissue layer for added stability. Throughout the process,
Trummer reported minimal discomfort, primarily from the expander. Post-surgery, his physical and psychological wellbeing signifi cantly improved, bolstering his self- assurance and overall quality of life.
University Hospital, and in Israel at the Tel-Aviv Sourasky Medical Center. “We also see the FDA thinking about how we [3D Systems] can do point-of- care printing in hospitals in the US,” Leonhardt adds. “We are also seeing more traction from industry partners across Europe as well as patients with skull defects.” Leonhardt envisions that the
FDA clearance will herald in a new era of implant technology. “With this technology, we can enhance implants with features like bone or lattice structures, tailored to each patient,” he explains. “Moreover, we’re able to achieve this while reducing costs, shortening lead times, and revolutionising the supply chain by
enabling on-site printing in hospitals.” Placing 3D printing systems within
hospitals fosters closer collaboration with surgeons, Leonhardt notes, while ongoing innovation expands the array of medically compliant materials available. “This technology empowers us to craft cutting-edge implants, democratising access to advanced healthcare,” he emphasises. “Ultimately, patients benefi t from faster, more aff ordable, and high- quality implants, enhancing their quality of life.”
For more information visit
www.3dsystems.com
www.engineerlive.com 13
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