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INDUSTRY FOCUS MEDICAL & PHARMACEUTICAL


how 3d priNtiNg accel iN medical device ma


Healthcare is one of the fastest-moving


industries for innovation, and medical device manufacturers need new ways to bring


high-quality, reliable, products to market more quickly. Dr. Gautam Gupta, senior vice president


& general manager, Medical Devices, 3D Systems, examines the role 3D printing can play


3 An orthopedic hip implant


D printing technology as part of a full additive manufacturing (AM) solution has long been recognised for its ability to


improve design freedom for implants and instruments, enhancing the functionality of the devices. With changing industry demands, the technology can also assist in lowering the overall cost of manufacturing these devices by reducing factory footprints. This is possible as several traditional manufacturing operations. such as forging and subsequent surface coating technologies. can be integrated to produce superior and more cost-effective devices. In addition, 3D printing can facilitate supply chain management through flexible lot-size production and reduce inventory on the shelf. And, by reducing the number of manufacturing steps, the OEMs can reduce the number of suppliers


and the overall turnaround time from PO to parts on the shelf. Industry-leading medical device


manufacturers are adopting AM to help in the development of innovative medical devices and instrumentation. One such manufacturer is rms Company, one of the largest contract manufacturers of high-quality, tight-tolerance medical devices in the world. For more than 50 years, the company has built a reputation as a premier manufacturer of medical device components using conventional subtractive manufacturing. Four years ago, it saw an opportunity to offer more to its customers through additively manufactured implants that deliver functionalities that cannot be achieved using traditional manufacturing methods. The company recognised that the


adoption of AM can be complex and, to do it well, the support of an external partner would be needed.


streamliNiNg the process


rms Company was methodical in its selection of an additive manufacturing solutions provider – looking for a partner that could help reinforce and extend its reputation for world- class quality. After careful evaluation, it chose 3D Systems based on the team’s deep experience in the healthcare industry and the


3D Systems’ direct metal printing (DMP) systems ensure exceptionally strong and accurate parts with high chemical purity, and the repeatability needed to produce implants for medical device OEMs


3 DESIGN SOLUTIONS MARCH 2023 6


company’s track record of success in developing healthcare applications. In fact, 3D Systems has manufactured over two million medical devices and has supported 100+ FDA-cleared and CE-marked devices. Over the course of four years working together,


3D Systems has helped rms expand its portfolio of direct metal printers from one machine to more than 30 – backed by a process that ensures repeatability across machines and supply chains – enabling the company to provide a complete Powder to Packagecapability to medical device OEMs. Powder to Packageencompasses the entire manufacturing and post-processing workflow required to go from a digital file to a sterilised and packaged final product ready for the surgical suite. In addition to industry-specific AM expertise,


3D Systems provided an ideal additive solution in terms of print quality and material properties, which was critical for parts like the implants rms produces. The best-in-class oxygen levels (<25 ppm) and inert printing atmosphere of 3D Systems’ direct metal printing (DMP) systems ensure exceptionally strong and accurate parts with high chemical purity, and the repeatability needed to produce implants for medical device OEMs. The DMP systems have become an integral part of rms Company’s Powder to Packagesolution which provides a complete end-to-end value proposition that allows them to control the entire manufacturing and packaging process flow.


New horizoNs aNd 50% iNcrease iN productivity


rms recently added the DMP Flex 350 Dual to its production workflow which can enable 50% productivity increases. This will enable the company to increase throughput for smaller implants, such as those intended for spinal applications. The medical device manufacturer also believes the productivity increases will also open new opportunities in the production of large joint and extremity implants while allowing flexibility for existing projects.


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