Company insight
3D printing enables improvements in spinal surgery
The market for interbody cages is growing, with over 1.6 million spinal procedures annually. While titanium alloys have been the primary choice for 3D-printed implantable devices to date, high-performance thermoplastics are gaining a reputation as game changers in the treatment of adult spinal deformities. 3D Systems works with device manufacturers and health systems to put these new materials to good use.
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he dawn of innovation in 3D printing has given rise to many materials that are applicable when it comes to life-changing surgery, enhancing surgical outcomes and patient comfort. This is clear in medical applications relating to the spine, where thermoplastics are able to provide an alternative to titanium and other materials, and improve upon them in a number of ways.
Tailor-made interbody cages A new extrusion platform called Kumovis R1 allows manufacturers to 3D print interbody cages in biphasic calcium phosphate-enhanced PEEK (BCP-PEEK), a strong thermoplastic with BCP to enhance cell attachment and proliferation. Interbody cages maintain intervertebral height, restore stability and promote bone fusion in spinal procedures. Traditionally, surgeons choose from standard stock cages to select one that most closely fits the patient, but BCP-PEEK cages can be printed to fit the individual’s exact anatomical requirements.
Resterilisable trial spacers Surgeons use trial spacers to evaluate the spacing between patient vertebrae. With so many variations in shapes and sizes required during procedures, lightweight polymer spacers are a welcome innovation in the operating room. Trial spacers printed in Radel polyphenylsulfone (Radel PPSU) can be sterilised and reused up to 500 cycles and feature colour coding to make the sizing process easier. Because of their lighter weight, spacers in PPSU are cheaper to ship and easier to stack and move between operating suites than
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3D-printed interbody cages in PEEK with biphasic calcium phosphate enhance cell attachment and proliferation.
traditional spacers. With the addition of barium sulfate filler, they are just as visible under X-ray as their metal counterparts.
Radiolucent bone plates Bone plates printed in carbon fibre- reinforced PEEK (CFR-PEEK) have higher strength than virgin PEEK and can be a replacement for metal-printed bone plates. Unlike metal materials, CFR-PEEK is radiolucent. CFR-PEEK implant innovations give surgeons the best of both worlds: the translucent properties of thermoplastics with the high strength and mechanical properties similar to human bone.
Patient-specific interbody devices As polymer-based spinal innovations ramp up, we’re seeing an acceleration in 3D-printed metal innovations as well. Additive manufacturing enables the design of porous scaffolds and intricate lattice structures. It also allows the production of personalised interbody
devices. Patient-specific interbody cages in titanium have demonstrated better bone grafting and spinal alignment than standard devices. Plus, ongoing improvements in direct metal printing and multi-layer print platforms are driving down the costs of manufacturing. Additive manufacturing makes it possible to control factors such as porosity, surface roughness, surface area and even endplate stress, resulting in complex structures that wouldn’t be possible with conventional manufacturing methods. New choices in materials add even more opportunities for innovation. 3D Systems help device manufacturers and providers evaluate the possibilities and work through the complexity. The company’s team of experts – called the Application Innovation Group – collaborates with healthcare innovators, expediting the path to FDA submission and beyond. ●
www.3dsystems.com/medical-devices Medical Device Developments /
www.nsmedicaldevices.com
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