Company insight
3D-printed ceramic surgical and medical tools
Ceramic tools unfold their potential where metal devices start to fail. Not only are they extremely heat and wear-resistant but also perfectly biocompatible and be easily sterilised. Designs of ceramic surgical tools have been strongly limited by traditional manufacturing methods as these are typically only economical if used for large quantities. However, ceramic 3D printers from Lithoz combine a new dimension of design freedom with scalable and efficient mass production.
n medicine, manufacturers can unlock previously unachievable qualities not only in geometry, but also economically. Large and small quantities of tools can be quickly and efficiently manufactured, while the many 3D-printable ceramics already in use in medical applications, including alumina, zirconia, silicon nitride and ATZ, greatly expands the range of possible innovative devices.
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One example of 3D-printed ceramics is an arthroscopic knee shaver. Conventionally, these shavers are manufactured from metal in a simple tube, but in this example, the shaver tip has an integrated channel for optical fibres, allowing constant illumination upon the critical area. Such channels could also be used for rinsing, suctioning or for wiring an electrocautery tip. Burrs for dental applications made
of ATZ highlight the limitless possibilities
by combining cutting-edge geometries with the hardness and expanded durability of ceramics, and also avoid metal debris during operations – important for metal-free surgeries. These parts, manufactured on the Lithoz CeraFab S65 Medical 3D ceramic printer with its 40µm resolution, offer enough detail to design precise and complex parts and a build envelope for efficient high-volume production. Over 100 burrs can be manufactured in one print run, meaning an individual burr is less than €10 ($10.7).
Limitless possibilities The German company Steinbach, a pioneer in ceramic 3D printing, recently showcased a 3D-printed ceramic tube printed with Lithoz technology for use in the Da Vinci surgical robot. Here, 12,000 tiny but high-precision tubes with sharp bends and inner
contours to feed optical fibres through, featuring perfectly smooth surfaces with roughness values of 0.4 µm and minimal wall thicknesses of 200 µm. This success shows how Lithoz ceramic processes have already successfully scaled to large serial production. Lithoz is already working on the simultaneous 3D printing of multiple materials in one single component. One example can be seen when looking at bipolar tweezers for electrocauterization, a surgical method to cut through tissue or stop vessels from bleeding. Here, ceramic and metal are printed together to combine the powerful insulating capabilities of ceramics with the conductive properties of metal. Such parts that once were impossible to build are now being successfully printed on a Lithoz CeraFab 2M30 Multi and can be experienced live at the forthcoming Formnext in Frankfurt, Germany (Hall 11.1, Booth D48). Ultimately, the rise of ceramic 3D-printed surgical tools marks a transformative chapter in modern medicine. With their precision, durability, biocompatibility and cost- effectiveness, these tools can entirely reshape surgical practices, streamline production and enhance patient care. As research and development continues, the medical community can look forward to a future where surgical precision and patient well-being are elevated to unprecedented heights through the fusion of ceramics and cutting-edge 3D printing technology. ●
Lithoz 3D-printed ceramic arthroscopic knee shaver has an integrated channel for optical fibres. 52
www.lithoz.com Medical Device Developments /
www.nsmedicaldevices.com
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