Medical 3D Printing Benefits Patients and Hospitals

Studies show that 3D printing in medicine is extremely effective. Products like 3D printed medical models and surgical guides decrease time in the operating room, saving thousands of dollars per case. Longer surgical procedures may also be reduced by as much as 2.5 hours. 

Medical 3D printing is projected to reach $5,846.74 million by 2030, growing at a CAGR of 20.10% from 2021 to 2030. Originally created for engineers to enjoy the rewards of faster prototyping and product development in the mid-80s, additive manufacturing has made impacts in nearly every application. The strides made in 3D printing for medical use are exceptionally valuable, however. One of the greatest benefits of 3D printing in medicine is the ability to offer patient-specific treatment.

“ … 3D printing technology caters to the rise in demand for personalized medical care by providing customized medical devices based on individual needs,” confirms Allied Market Research. “Furthermore, it provides several advantages over traditional reconstructive surgeries by reducing the operative risks involved during complex procedures, minimizing the susceptibility to infections, and decreases the duration of anesthesia exposure.”

3D Printing for Medical Diagnostics

3D printing in medical begins with imaging, translating 2D data into models and other medical devices. Historically, doctors relied on medical imaging like X-rays, Computed Tomography (CT) or Magnetic Resonance Imaging (MRI) to diagnose and treat patients. This data can be taken to another level with 3D printing for examining serious conditions like brain tumors, heart defects, or bone fractures. Patient-specific treatment begins with the 3D printed medical model–a personalized device offering a multitude of benefits. Surgeons are able to get a 3D look at the patient’s condition; for example, they may be examining a brain tumor or a heart defect. Taking an intricate look at the health issue, doctors can begin formulating a treatment plan. The 3D printed medical model also serves as a comprehensive visual aid for patients and their families, educating them on the patient’s condition and potential surgery. In some cases, a surgeon may be preparing for a new or rare surgery, spending hours training with the model–and even using it as a guide in the operating room. Medical students can also gain valuable knowledge training with 3D printed medical models.

Companies like Armor Bionics design 3D models, relying on Shapeways to 3D print them in durable material like Nylon 12 [Versatile Plastic] with Selective Laser Sintering technology. Their manufacturing partnership allows for both companies to focus on their expertise, providing a fast and effective process for working with doctors and hospitals. Because human lives are involved, the Armor Bionics team is not shy about rapid prototyping and creating as many iterations as needed to reach the detail and accuracy required for their models–often described as a GPS for surgeons.

The team at Armor Bionics reports that the advantages are impossible to ignore. The Armor Bionics 3D printed models enhance pre-planning for what may be delicate operations, allowing everyone involved–from patients to doctors to medical staff–to benefit tremendously. With access to such accurate models, doctors can shorten operating and recovery times, and reduce margins in error due to more precise diagnostics and tools.

Other recommended materials for 3D printed medical models include:

High Definition Full Color – Offered for photorealistic 3D printed medical models, this material is available in a staggering range of ten million hues, available in standard or matte finishes. 3D printed with Material Jetting technology, High Definition Full Color anatomical models represent the human body in exacting detail. Learn more about this 3D printing material and design guidelines here.

Multi Jet Fusion PA12 – Also popular for 3D printing complex medical models, MJF PA12 is available in gray and black. Shapeways 3D prints MJF PA12 using Multi Jet Fusion technology, creating strong, durable medical models capable of standing up to long-term handling. Explore the design guidelines here.

3D Printing for Medical Training

Elevating the 3D printed model for surgical training, companies like Flamingo Works partner with Shapeways to provide doctors with gamified learning devices. As robotic assistance continues to evolve in the operating room, more advanced training systems are also necessary for refining new skills and dexterity.

3D printing has made it possible for the industrial designers to develop unprecedented gamified systems that are colorful, engaging, and effective. In choosing Selective Laser Sintering (SLS) 3D printing with Shapeways, their team was afforded greater design freedom without the need to create intricate support structures. Flamingo Works 3D printed many of the surgical training platforms during the prototyping phase. They were able to iterate quickly, 3D print new parts, and test them soon after they were complete for form and functionality.

Nylon 12 [Versatile Plastic] allowed for the necessary durability required with repetitive use of the training models presenting different surgical tasks with increasing levels of challenge. 3D printed SLS parts made with Nylon 12 [Versatile Plastic] can also be dyed in nine different colors during post-production.

3D Printing Enhances Medical Equipment

The possibilities in 3D printing for medical applications are infinite, encompassing a wide range of accessories. When Steven Jaworski of Voytek Medical began creating clasps to organize medical equipment cables, the engineer was motivated to increase efficiency in the hospital setting. Rather than allowing medical equipment to be out of service due to missing components, Jaworski realized there was an easy fix to keep parts secure–and machines functioning. 

The long-term savings are tremendous in the hospital setting, especially in asset protection, saving cables that could be lost or thrown out, including those bearing warranties. 3D printed medical equipment accessories like cable clasps make it possible for staff to perform their jobs more easily, and medical equipment companies are able to maximize longevity of equipment and peripheral accessories. 

Voytek’s 3D printed medical clasps are highly customized and can be color coded for maximum efficiency in diagnostics and patient care, as well as delineating parts that belong to different departments. Additive manufacturing makes it possible to scale orders, reduce assembly, and accelerate turnaround times.

Working with Shapeways granted Voytek accessibility to more advanced 3D printing technology and materials. Again, the freedom in design afforded via SLS 3D printing for medical meant that Jaworski could create sophisticated designs that are strong yet also lightweight. Partnering with Shapeways gave Jaworski more time to focus on design, building his brand, and marketing. 

On-Demand Medical 3D Printing

3D printed medical equipment designs can be maintained on digital file at Shapeways and manufactured on demand. The ability to order products as needed can play a huge role in the success of any manufacturer, allowing them to make changes and customize to scale.

With Shapeways, 3D printed medical products can be manufactured quickly and delivered in customized packaging to manufacturers or their own customers. Other major benefits of on-demand 3D printing for medical include security in uploading, maintaining, and storing inventory of customized parts. Production is optimized for higher quality and output, promoting savings in material and energy too. The supply chain is streamlined, manufacturers have more control, and distribution is a focus. 

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post Medical 3D Printing Applications and Benefits appeared first on Shapeways Blog.

3D Printed Medical Models and Tools

Successful treatment begins with gathering as much information as possible about a patient and their physical condition. While the ability to see inside the human body before surgery previously relied solely on X-rays, computed tomography (CT) scans, and magnetic resonance imaging (MRIs), diagnostics have been expanded much more fully with 2D data converted into complex 3D printed medical models. 

3D printed medical models serve multiple functions. Once a diagnosis is attained, the 3D printed medical model offers advanced guidance for treatment; for example, a detailed anatomical model may display a tumor in the chest, a defect in the heart, or deformations in major joint areas like the knees or hips. At that point, doctors have the benefit of using 3D printed models as powerful visual aids to educate patients and their families, demonstrating what a possible medical procedure or treatment plan may entail.  

The learning benefits are extensive with 3D printed models, to include extremely valuable training for medical students who are able to view a tumor, for example, and then practice what could be a new or rare surgical procedure. An experienced surgeon may also rely on the 3D printed model for the duration of the treatment, practicing and training extensively for the procedure. 

3D printed medical models are becoming increasingly more common in pre-surgical planning, and in the operating room. Surgical guides lead to elevated confidence and even better accuracy on the part of the surgeon, also reducing the amount of time spent in the operating room.

Shapeways recommends the following materials for 3D printed medical models:

High Definition Full Color – One of the most exciting options for photorealistic 3D printed medical models, this material is available in ten million colors, with options available for Standard or Matte finish. Produced via Material Jetting (MJ) technology, anatomical models 3D printed with High Definition Full Color represent human organs in exacting detail. Find out more about the design guidelines for this material here.

Multi Jet Fusion PA12 – Also suitable for the creation of complex medical models, this versatile material 3D printed with Multi Jet Fusion offers both strength and durability—both important characteristics for parts that tend to be handled a lot over time. MFJ PA12 is available in Black and Gray, with options for Natural or Smooth finish. Find out more about the design guidelines for MJF PA12 here.

Customized 3D Printed Medical Devices and Implants 

While medical models make patient-specific treatment possible, 3D printed devices such as implants are actually custom-fitted to patients, eliminating the one-size-fits-all mentality. A diverse number of 3D printed devices are available via advanced technology and materials, and the greatest benefit is still centered around the ability to offer substantially greater form and fit with personalization. These advantages are especially evident when a newborn’s life is saved with a 3D printed implant, a high-performance prosthetic is used as a limb replacement, or surgeons are using new 3D printed training tools for complex medical procedures.

For prosthetics and orthotics, the additive manufacturing process begins with a quick 3D scan. With perfectly calculated form, a 3D printed part is made-to-fit for the patient. Whether 3D printing orthotics or prosthetics, this process is extremely helpful for children who may not only have an exceedingly difficult time remaining still for long fittings, but are also growing at such a rapid rate, they could outgrow a device before it is even delivered. While the 3D design and printing process is exponentially faster, if changes must be made there is a huge difference between having to order a completely new device or just making a swift modification to a 3D file and making another 3D print.

Shapeways recommends the following materials and technology for 3D printed orthotics and prosthetics:

Nylon 11 [PA11(SLS)]- 3D printed with Selective Laser Sintering (SLS), this material is durable and offers good resistance to impact as well as high tensile strength. Nylon 11 [PA11(SLS)] is offered in White, with a Standard finish. Explore the design guidelines for this material further here.

Nylon 12 [Versatile Plastic] – Also relying on SLS 3D printing, this material is extremely durable and adaptable, whether parts require rigidity or flexibility. Nylon 12 [Versatile Plastic] is available for dyeing in eight different colors with a variety of finishes ranging from Standard to Premium and Smooth. Explore the design guidelines for this material further here.

Multi Jet Fusion PA12 – Also suitable for prosthetics and orthotics, this versatile material 3D printed with Multi Jet Fusion offers strength and durability—both important characteristics for parts that tend to be handled a lot over time. MFJ PA12 is available in Black and Gray, with either the Natural or Smooth finish. Find out more about the design guidelines for MJF PA12 here.

3D Printed Gamified Learning with Robotics for Surgeons

Although 3D printed medical models play a tremendous role as educational visual aids, companies like Flamingo Works have expanded on learning for surgeons by 3D printing extensive platforms that are set up like colorful games. Advanced enough to challenge doctors into climbing to the next level, gamified learning builds on the dexterity required for complex, robot-assisted medical procedures. 

Designing for Nylon 12 [Versatile Plastic] with SLS technology, founders Yonatan Assouline and Naty Moskovich developed the concept for their unique 3D printed educational tools after a long-time robotics client approached them to make a simulator for robotic surgery training. Taking a new approach, the industrial design team aimed to avoid the typical anatomical cadaver-like training with silicone. Instead, they chose small, open platforms to create challenging exercises for surgical mastery of  robotic grippers.

3D Printed Organizational Tools for the Medical Setting 

Exemplifying just how many roles 3D printing can take on in medical applications, Voytek Medical has made a real case for the importance in organizing detachable medical equipment cable. Anyone who has ever been in a hospital is familiar with the plethora of cords scattered around and in constant use. 

Partnering with Shapeways to design and 3D print clasps for locking medical cables in place, Voytek founder Steven Jaworski was able to offer a real solution for hospitals to better manage and maintain critical medical equipment. Rapid prototyping also played an important role as Jaworski perfected his innovative products, improving workflow for medical professionals who now no longer have to worry about finding or piecing equipment together during a patient emergency.

3D printing has made its mark in a multitude of diverse, global applications, paving the way for innovation and unprecedented product development. 

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post Medical 3D Printing: Patient-Specific Customization for Perfect Fit appeared first on Shapeways Blog.

Automotive 3D Printing

Automotive is one of the fastest-growing industries harnessing the power of additive manufacturing; however, carmakers and 3D printing go way, way back who have taken great advantage of such technology behind the scenes, far before many others even knew what 3D printing was. 

Initially, rapid prototyping was the key element drawing the attention of automotive manufacturers, and still serves as an extremely valuable part of product development. There are still plenty of companies who have yet to institute AM processes for prototyping—but most large, as well as luxury-oriented automotive companies—are not only using AM in product development but also for high-performing, functional products too, both for the interior and exterior. 

For car-owners, this means very specific style and comfort inside the car, from headrests to seats, along with other interior features to be 3D printed like dashboard components and gear-shifting devices. Shapeways customers like 67 Designs are famous for their 3D printed mounting systems, allowing tablets to be held in place on the dashboard for filming incredible off-roading adventures.

Shapeways offers advanced materials and technology suitable for automotive 3D printing, to include:

• Nylon 6 Mineral Filled (PA6MF) – PA6MF is used in highly industrial applications due to great strength, stiffness, impact resistance and heat stability. The mineral-filled reinforcements offer properties similar to injection molded parts, 3D printed with Selective Laser Sintering (SLS) technology.
• Nylon 11 [PA11(SLS)] – Available in white, this nylon material is both durable and flexible, making it popular for 3D printing in automotive applications, using SLS technology.
• Nylon 12 [Versatile Plastic] – One of the most popular industrial 3D printing materials overall, Nylon 12 [Versatile Plastic] is used for unlimited prototyping as well as functional parts–including the 67 Designs Magmount.
• Polypropylene – Available in gray, Polypropylene is also a versatile material for automotive parts, offering great resistance to chemicals, low moisture absorption, and excellence in durability. This material is 3D printed with SLS technology.
• Thermoplastic Polyurethane (TPU) – Available in gray, TPU offers superior tensile strength, good load-bearing capacity, and excellent resistance to chemicals, oil and grease, weather, heat, and abrasion.  TPU is 3D printed with either SLS technology or Multi Jet Fusion.

3D Printed Drones

Our urge to fly is a never-ending quest, evidenced by continued innovation in aerospace, as well as drone technology. Although flying may not always be safe for the drone, one great benefit in designing and flying an Unmanned Aerial Vehicle (UAV) is that the human remains firmly planted on terra firma while wielding the controls. Meanwhile, the vast skies continue to become just a little more populated by new drone designs every day. 

Aside from the growing potential for consumer deliveries, drones are already in use for industrial tasks, to include use in real estate surveying, as well as for agricultural and crop applications. Drones are used for mapping, as well as search and rescue missions which may include dropoff of supplies when other humans are unable to get to a remote location. 

Shapeways offers numerous materials and technologies which are recommended for 3D printing drones, to include the following:

• Aluminum – Materials like aluminum are recommended for high-performance parts required for aircrafts like drones due to incredible strength and durability. Even better, aluminum is lightweight enough to allow sleek drone designs to fly at maximum speeds.
• Multi Jet Fusion Plastic PA12 is a nylon thermoplastic recommended for drones due to its strong and lightweight nature, featuring superior mechanical properties, and good support for intricate structures. MJF Plastic PA12 is available in black or gray, with the option of a smooth and glossy finish.
• Nylon 11 [PA11(SLS)] – Available in white, this nylon material is both durable and flexible, making it popular for industrial applications, 3D printed with SLS technology. This additive manufacturing thermoplastic is particularly appealing to drone designers because of its resistance to impact–definitely an important trait in aerospace technology.
• Nylon 12 [Versatile Plastic] – One of the most popular industrial 3D printing materials overall, Nylon 12 [Versatile Plastic] is used for unlimited prototyping as well as functional drone parts, favored by Shapeways customers like Kespry and Quantum-Systems. This material is also relied on for quality 3D printing of large drone parts. Nylon 12 [Versatile Plastic] boasts the ability to act flexibly for thinner parts and more solidly for thick structures. Available in a wide range of colors for dyeing parts, and a variety of 3D printed finishes, Nylon 12 [Versatile Plastic] is 3D printed with SLS technology.

Full-Color 3D Printed Gaming Miniatures

There are hundreds of millions of gaming enthusiasts in the US, and you would be hard pressed to find one who is not already well aware of 3D printing technology and all that it brings to the industry. Recreation like gaming brings in billions of dollars worldwide each year, and is currently still expected to grow at a compound annual growth rate (CAGR) of 13% through 2026.

Tabletop gaming involving role-playing has experienced a resurgence, with more players than ever taking time out to indulge in fantasy worlds filled with adventure, strategy–and full color miniatures for enthusiasts who want to bring their characters to life. Because these 3D printed pieces are often used for many games or expected to last as collectibles, they must be more durable and able to hold their color. Gamers and manufacturers often 3D print custom game pieces, boards, and accessories too.

The following materials are suggested for 3D printed gaming products:

• High Definition Full Color – Available in ten million colors, this material is used to create incredibly detailed figurines for gaming with amazing textures–as well as associated pieces like game pieces, dice, and more. High Definition Full Color is 3D printed with Mimaki technology relying on Binder Jetting.
• Nylon 12 [Versatile Plastic] – One of the most popular industrial 3D printing materials overall, Nylon 12 [Versatile Plastic] is used for prototyping as well as creating final products like miniatures. Available in a wide range of colors for dyeing parts, and a variety of 3D printed finishes, Nylon 12 [Versatile Plastic] is 3D printed with SLS technology.

Medical Applications for 3D Printing

3D printing has made tremendous impacts on the medical field, beginning with 3D printed models. With the ability to educate everyone involved in any case, 3D printed models have transformed processes such as diagnosing; for instance, with a CT scan or MRI converted into 3D, a surgeon can get a much deeper perspective on a condition like a brain tumor. 

Diagnostics and treatment are much more streamlined, and the anatomically correct, 3D printed medical model can be used as a visual aid for explaining to patients and their families about the condition and any upcoming procedure. Surgical tools and guides can be created too. Again, completely patient-specific treatment is available as medical devices can be customized for the patient and procedure–whether it is a joint replacement or a dental operation.

3D printed prosthetics and orthotics have offered huge benefit to patients around the world in need of limb replacements. With the ability to work quickly from a 3D scan, designs can quickly be engineered to fit growing children, as well as adults who may have never had a 3D printed orthotic or prosthetic that they were proud to wear.

Typical materials recommended for 3D printing in medical applications include:

• High Definition Full Color – Available in ten million colors, this material is used to create incredibly detailed medical models in photo realistic detail. High Definition Full Color is 3D printed with Mimaki technology relying on Binder Jetting.
• Multi Jet Fusion Plastic PA12 – This material is known for excellent mechanical properties, strength and durability, and the stiffness required for 3D printing orthotics, prosthetics and other customized medical products. This material is also lightweight and offers good support and stability for intricate designs. Available in black or gray, Multi Jet Fusion technology is used to 3D print Multi Jet Fusion Plastic PA12.
• Nylon 11 [PA11(SLS)] – Available in white, this nylon is both durable and flexible, making it popular for 3D printing in medical applications, using SLS technology. This 3D printed thermoplastic is particularly appealing because it is biocompatible, durable, and offers excellent impact resistance.
• Nylon 12 [Versatile Plastic] – Extremely popular in medical applications, Nylon 12 [Versatile Plastic] is used extensively for creating models, along with highly customized, functional surgical tools. Nylon 12 [Versatile Plastic] also boasts the ability to act flexibly for thinner parts and more solidly for thick structures. Available in a wide range of colors for dyeing parts, and a variety of 3D printed finishes, Nylon 12 [Versatile Plastic] is 3D printed with SLS technology.
• MJF Plastic PA12 Glass Beads – Commonly used with Multi Jet Fusion technology to 3D print medical devices like braces for the hands, arms, or legs, this material is 40% glass-filled, offering superior accuracy and strength.

Robotics and 3D Printing

For so long, robotics have been predicted to play a huge role in the future, whether running entire factories, building colonies on the Moon or Mars, As humans have steadily been planning out tomorrow, however, robotics have become very entrenched in the industrial applications of today, and often act as a complementary technology to 3D printing. The technologies have evolved together, with no signs of slowing down. 

Within robotics, 3D printing can be used in a number of ways. Initially, prototyping is a huge benefit in robotics. Offering the ability for any designer or engineer to iterate as required, product development is streamlined with models and prototypes produced faster, tested faster, and with valuable feedback given expeditiously. High-performance robots can be created with 3D printing, as well as products like 3D printed robotic hands, arms, legs, and a variety of different bionic items. Electronics can be embedded into 3D printed parts also. Finally, many different types of robotics modifications can be developed, to include housings and parts, tooling and jigs, and replacement components.

Shapeways recommends 3D printing robotics materials like:

• Nylon 6 Mineral Filled (PA6MF) – Available in black, PA6MF is used in 3D printing robotic applications due to great strength, stiffness, impact resistance and heat stability. The mineral-filled reinforcements offer properties similar to injection molded parts, 3D printed with Selective Laser Sintering (SLS) technology.
• Nylon 11 [PA11(SLS)] – Available in white, this nylon material is both durable and flexible, making it popular for robotics applications that are 3D printed with SLS technology.
• Nylon 12 [Versatile Plastic] – One of the most popular industrial 3D printing materials overall, Nylon 12 [Versatile Plastic] is used for unlimited prototyping as well as functional robotic parts–including parts for customers like Flamingo Works, creating incredibly complex and dynamic, 3D printed gamified training models for surgeons.
• Polypropylene – Available in gray, Polypropylene is also a versatile material for robotic parts, offering great resistance to chemicals, low moisture absorption, and excellence in durability. This material is 3D printed with SLS technology.

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post Five Industrial 3D Printing Applications On the Rise appeared first on Shapeways Blog.

“It’s nice to know that Shapeways has their quality control standards so high I don’t have to worry.” – Steven Jaworski, Owner of Voytek Medical

The improvements and industrial solutions available through the freedom of 3D design and the versatility of 3D printing are nothing new to Steven Jaworski, biomedical engineering technician, and owner of Voytek Medical. A pioneer in creating 3D printed organizational tools for medical equipment, Jaworski was prompted to learn CAD design, buy his own 3D printer, and even an injection molding machine while grappling with products and solutions that had been much-needed for a long time.

Working in healthcare means access to a lot of cables, most of which are meant to stay attached to their corresponding medical equipment; however, in a fast-paced environment, detaching a cable and attaching it to another piece of equipment in another department can be common practice. This is understandable as medical professionals are in the act of treating patients and in some cases, working fast to save lives. The overarching problem though is a never-ending cycle of frustration in dealing with a substantial percentage of machines that aren’t in working order. When all parts are intact, equipment can be much more easily maintained, and clinicians have increased confidence in the machines they are using daily to take care of patients in need of diagnostics and treatment. 

One missing cable has the ability to cause an escalating effect, especially in a medical setting where it is not uncommon to have a sense of urgency. Initially, Jaworski was spending an inordinate amount of time replacing medical cables in healthcare. The repetition led him to the realization that they not only needed to be organized, but clamped in place with an innovative piece of hardware.

“One bad or missing cable can mess up everything around it,” said Jaworski. “Clinicians should be able to rest assured that when they need a piece of equipment to monitor a patient, all the required parts are attached. They shouldn’t be hunting around for compatible cables.”

3D Printed Cable Clasps Offer Substantial Savings to Hospitals

Defining a more streamlined way for healthcare providers to maintain control over critical cables and ongoing maintenance and longevity for medical equipment, Jaworski went to one of the facilities he worked for and explained the need for an easier way to do things. It wasn’t hard at all for Jaworski to sell his idea, pointing out how expensive medical cables are and how many were going missing annually.

“I was able to prove a business plan, made a preliminary part, and we went through a series of designs to make the cable clasps stronger,” said Jaworski, who continued to refine his benchmark part, along with being given permission to take the intellectual property and patent his design soon after.

With a degree in graphic design behind him, the visionary for Voytek was well-versed in 2D design, but he had entered a brave new world and taken on a lot in a very short time in exploring 3D design, as well as 3D printing—a technology that was just hitting the mainstream around 2015.

While tinkering around at the desktop served its purpose initially, Jaworski quickly realized he was going to need more advanced technology, materials, and expertise, even just for prototyping and expanding product development. Although the idea of performing product development and manufacturing all by himself was appealing at first, soon he was ready to trade in the tedium of desktop 3D printing for industrial 3D printing. Working with Shapeways meant moving up to more advanced 3D printing technology and materials, as well as giving Jaworski more time to focus on specializing in design, building his business brand, and marketing his product.

Shapeways Industrial 3D Printing Proved Transformative

Ultimately, industrial 3D printing was the key, and the perfect fit, for manufacturing the evolving 3D printed cable clasps. In handing over his models for Shapeways to 3D print, Jaworski was able to rely on an efficient platform for prototyping, uploading new designs, and receiving parts expediently, whether during iteration or in preparation for shipping to customers. The process did indeed begin with many, many iterations, a process made possible due to the long-time expertise of Shapeways, and experience in working designers and engineers who at times may prefer to make over a hundred iterations of a part for the ultimate in precision and quality. 

“It’s such a simple design and such a simple thing, but because of the value that it has I had to make sure everything was perfect,” said Jaworski. “Just think how embarrassing it would be if someone purchased a device, and then they opened it and closed it, and the parts didn’t line up. Achieving perfection is tough.”

Selective Laser Sintering (SLS) and Nylon 12 [Versatile Plastic] played an enormous part both in iteration as well as 3D printing end-use parts. The freedom of design afforded through SLS 3D printing specifically meant that Jaworski was able to attain complex, lightweight designs not possible through traditional manufacturing like injection molding–a technology he had explored quite thoroughly already.

“I’ve tried injection molding, and I actually own an injection molding machine. I had a mold made for one of my designs and I could not get it to line up due to warping,” said Jaworski. “It all comes down to quality. It’s extremely difficult to sell something for the price it needs to sell at if it isn’t made right and doesn’t look right.”

SLS 3D printing requires no supports, meaning that designers and engineers like Jaworski don’t have to worry about creating intricate structures to stabilize parts during printing; furthermore, supports don’t have to be removed in post-processing either, posing the potential for damage later. A powder-based technology able to 3D print on nearly any scale, SLS is fast, powerful, and well-matched with materials like Nylon 12 [Versatile Plastic]. 

A 3D printing material that offers many features for industrial manufacturing, Nylon 12 [Versatile Plastic] has been a great choice for Voytek products due to the strength and durability in parts, along with the lighter weight offered by nylon thermoplastics. Jaworski has also taken full advantage of the array of colors available, using them to color code products for different hospital departments so they are able to identify a clasp and a corresponding cord from across the room.

Shapeways Manufacturing Allows Voytek to Focus on Business

On-demand 3D printing played a huge role in the success of Voytek, allowing Jaworski to order customized parts as needed from a list of products he had already designed and tested. Shapeways 3D prints parts and then sends them to Voytek for assembly and shipping to hospitals. The quality of 3D printing materials like Nylon 12 [Versatile Plastic] has built a foundation for happy customers, with Jaworski reporting that he has tested the durability and strength himself–to extremes–and it always comes through.

“I’ve taken pliers to the parts trying to crack them, and have tested them with everything in the hospital,” said Jaworski. “The color never bled, and the material never became brittle. No issues. I have not received a request for a single repair, a complaint, or anything.”

“It’s nice to know that you guys have your quality control standards so high that I don’t have to worry. I rarely even count pieces anymore when I receive hundreds of parts, because I know it’s going to be right.”

Today, Jaworski is protecting nearly a million dollars in assets for hospitals, all revolving around medical equipment that allows patients to receive fast, quality treatment.

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post Voytek: 3D Printing Addresses Pain Points in Medical Applications appeared first on Shapeways Blog.

3D Printing in Medical Applications to Make a Difference

Shapeways began working with Voytek in 2015, just as 3D printing was really hitting the mainstream. In creating his 3D printed device for organizing medical equipment, Steven Jaworski, owner of Voytek, was able to garner financial support for his budding business; however, budgeting was critical so he planned to do everything himself. His concept and accompanying design were advanced enough for a hospital to trust in his product and invest, but manufacturing meant finding suitable materials and technology for creating parts strong enough to hold up under rigorous use in a healthcare facility.

The project, and the inception of Voytek Medical, were born out of frustration as Jaworski saw machines continually out of circulation, prematurely diagnosed as broken, when in reality they were just missing a cable. Part of the problem was that one department in need would ‘borrow’ from the other. Jaworski realized that hospitals were losing significant amounts of money every year because medical equipment and cables, quite simply, were not remaining connected as they should have. Even worse, medical personnel were not able to have faith in the equipment they needed to take care of patients. As a biomedical engineering technician, Jaworski realized his days could be much better spent doing much more than just replacing cables. First though, he had an idea, and a design, for locking everything into place.

“That’s the origin story,” says Jaworski, pointing out that, however, that when it came to the idea of using 3D printing in healthcare there was not a dramatic genesis; rather, even though the technology was new to the mainstream public, he had read about it in the media and understood it to be a viable option. Later, the hospital was amenable to his ownership of the intellectual property, and Jaworski had his design patented leaving him to experiment with product development as he saw fit.

On-demand, Industrial 3D Printing is Still Key for Voytek

As Jaworski began searching for options to manufacture his design, he tried a couple of alternative options through different companies, but the materials just weren’t industrial enough for the environment or the rigors of daily life in a healthcare facility.

“3D printers had just become more prevalent,” said Jaworski. “I had not used 3D printing before at all though, and that was my first attempt at CAD. There was a learning curve for sure.”

Difficulties eventually began to arise in terms of industrial needs that his desktop 3D printer simply could not fulfill though. In reaching out to Shapeways, Jaworski was able to create quality prototypes and then move on to manufacturing large volumes of his product.

With the ability to order 3D prints for medical applications on demand from Shapeways, there was no need to have a warehouse to store large volumes of inventory and all profits were put back into Voytek. A ‘menu’ of items was and is ready for customizing and 3D printing at any time, with options in terms of style and color and more for customers to enjoy. Because he was able to order what he needed on-demand, Jaworski was not only able to get the business up and running, but he was able to retain 100 percent ownership without having to go into debt. There were no upfront costs, no tooling costs, and no spending tens of thousands of dollars on molds for larger volumes he wasn’t sure about being able to move.

“The business built the business,” said Jaworski. “I was able to scale as needed, and constantly reinvested back into the company. Any kind of profit went into expanding the product itself, getting better tools, and even better work benches.”

And for the customers, the savings are well worth it–reflected by the growing number of return customers.

The ‘Menu’ of 3D Printed Clasps and Mounts

Working from Jaworski’s ‘menu,’ there are several typical clasps that can be 3D printed through Shapeways on-demand. This consists of different orientations, according to Jaworski, whether probes are being ordered for ultrasound machines, bed speakers, or other equipment. The 3D printed clasps featuring three holes are generally used for bedside monitoring operations, while the five-hole clasp is generally used for the ICU in terms of monitoring the patient.

Voytek also produces different types of 3D printed mounts. One might loop against itself, with the wire going through the mount and into the clasp where it screws in. That allows customers to attach it to anything with a handle. Other mounts may screw directly into a wall or any kind of hard surface. Another mount may fit into a standard track.

“Depending on what the order is, for any combination of those, Shapeways gives me the flexibility to order for that part. If a five-hole system is needed for a certain mount, I can just order exactly what I need rather than in bulk,” said Jaworski.

Selective Laser Sintering is used to 3D print all the Voytek products, using Nylon 12 [Versatile Plastic]. 

“We offer everything in the arsenal that you all have in Versatile Plastic,” said Jaworski, referring to the colors.

The colors are used to distinguish between the departments. This is very effective for identifying the 3D printed clasps from afar, without having to call the clinical engineering team to figure out if they have the right parts. 

Each clasp comes with a key to lock it in place, and is designed to work with all medical cables accompanying bedside monitors and roll stands. Voytek Medical products can quickly become indispensable in streamlining the office or hospital environment and even more importantly, these 3D printed products can be used without voiding any product warranties or requiring modifications to expensive equipment.

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post From the Desktop to Industrial 3D Printing: Voytek’s Journey to Success appeared first on Shapeways Blog.

In Increasing Your Production Power: Additive Manufacturing with EOS & Shapeways, the long-standing manufacturing partners and industry leaders outline the features of EOS materials, along with identifying the main benefits in developing products for additive manufacturing.

1. Selective Laser Sintering (SLS) is More Powerful than Ever

Relying on SLS 3D printing, EOS harnesses the power of powder-based technology targeted by lasers to solidify nylon particles, layer by layer, into the desired structure. Most SLS printers are large, and capable of printing an average of 500 to 1000 parts in a single build.

Most builds are made up of thousands of layers, resulting in detailed parts with intricate features. Shapeways uses popular nylon thermoplastics like Nylon 12 [Versatile Plastic] in partnership with EOS, along with other materials that according to Cary Baur, Senior Manager-Polymer Technology at EOS, are fairly common engineering plastics which translate well to other applications—including those that are also being used in traditional manufacturing methods like molding or machining.

One layer at a time is recoated at roughly 100 to 120 micron layers. Each layer of powder is deposited and then heated to just below the melting point.

“We use a directed laser in select areas to melt the materials and create the geometries that we want,” said Baur. “Essentially, we print in a two-dimensional method, but we do that in consecutive layers in the sense that we are building up a three-dimensional object. What this really does in terms of creating value is that it allows you to take a digital file and implement it in a way that gives you a huge design toolbox.”

2. Design Freedom is Huge

Freedom in design is boundless with SLS 3D printing. Supports are not required for this powder-based technology due to the bolstering effect of all the unsintered powder bunching up around parts during printing, stabilizing them throughout the process. This means that engineers don’t have to worry about factoring in support structures to the design process, and even better, production specialists don’t have to worry about fitting them in intricately to the print build—or risk the possibility of damaging parts during post-processing as supports are removed.

“We can 3D print lightweight parts that previously were very bulky because we couldn’t make custom lattices like we can now,” said Baur. “Now we can take those, reduce the mass dramatically, and also reduce material inputs.”

“There’s parts we used to have to machine and mold separately and assemble via different processes that all require more time and cost. Given our design freedom, now we can look at the process differently and design components to fit in with each other during printing.”

Complex parts can be made with better tolerances, greater efficiency, and may include dynamic, moving parts too.

3. The 3D Printing Journey Extends from the Concept to Reality

At the customer level, design begins with developing products for a specific application. After that, Shapeways is responsible for understanding the customer’s needs, revving up production, and providing solutions to scale for other manufacturers.

With the ability to eliminate tooling, 3D printing offers better cost optimization. Along with that comes great efficiency in the use of resources—namely, materials—as less are used in additive manufacturing as compared to subtractive, and much powder can be recycled in each build. Assemblies can be reduced in many cases, allowing for embedded functionality, and the ability to produce large parts all in one piece—meaning that quality and speed are improved, and there is also much less chance for error during production.

This is especially true during product development when many changes are continuing to take place. Projects are turned around swiftly, especially with the potential for quick feedback on virtual or tangible models, as well as haptic feedback.

“In comparison to the speed in 3D printing which takes hours or a few days, it can take months to create molds for traditional methods like injection molding,” mentioned Steve Weart, Director of Customer Success at Shapeways. “The time involved in production really adds up too if one or more changes need to be made.”

“Additive manufacturing makes more and more sense, especially in terms of being environmentally friendly. If we can make something locally, it really changes the game too.”

Shapeways customers are able to cater to the growing trend in demands from consumers for customized fit and customized treatment, whether in fashion or critical applications like medicine.

4. Low- to Medium-Volume Production Yields Great Efficiency

On demand 3D printing is a revolutionary concept, and one that is quickly gaining appeal and traction. With the ability to send Shapeways digital files and then set up customized 3D printing as needed whether for one part, low-batch production, or even mass production of parts, customers are able to avoid spending precious capital in buying their own 3D printing equipment and related materials, eliminate the need to keep inventory on hand or pay for warehouse space, and can even enjoy complete product fulfilment, as orders are shipped out directly in customized packaging.

“With a digital twin for parts on file, you can then just have a number of machines on standby ready to print parts on demand to keep company equipment up and running,” said Baur. “There is a very strong business case for converting as many aging parts as possible to digital files, so they are available when needed—and without having these massive warehouses full of aging parts and inventories just sitting there.”

SLS materials and technology are used in a wide range of applications, to include:

• Aerospace
• Consumer goods
• Electronics
• Eyewear
• Footwear
• Medical devices and medical equipment

The automotive industry is a good example of customized products that are in demand for low-volume production—especially for luxury cars where there may be a target audience for complex interior parts that can be made much faster and more economically than with a traditional method like injection molding. For many different parts, weight can be reduced enormously, saving economically and in efficiency.   

Medical devices like orthotics can also be made much more accurately for fit and functionality. Shape and density are improved with 3D printed products, with specific pressure-point areas and insoles that are designed for the weight and mass profile of the wearer. Performance is better, and customers are much less self-conscious due to more aesthetically pleasing choices. Being able to make a lightweight product is extremely important for orthotics too.

5. Customer Demand Drives Ongoing Product Improvement

Currently, Shapeways offers Nylon 12 [Versatile Plastic], Thermoplastic Urethane (TPU), and PA11. These materials are designed to offer flexibility in options for 3D printing, excellence in material properties, and ease in quality control and production.  

“Nylon 12 is our highest-volume material on the market right now,” said Baur. “Nylon 11 also is very popular for applications that require more dynamic mechanical strain and more compliance.”

“A large part of our business is helping to identify the needs of our customers specific to an application,” said Baur. “If we don’t have a current material that meets customer needs, we often can make it, and often we will help enable our customers by working with Shapeways to then look at a material and a production process, with Shapeways filling the production need with the EOS material.”

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for 3D printing with accuracy, complex detail, and no limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Top 5 Takeaways from 3D Printing Solutions Webinar appeared first on Shapeways Blog.

Vapor Smoothing

Accompanied by new choices with Nylon 12 [Versatile Plastic] Smooth, Shapeways customers can design for even more complex structures—whether in product development or for end-use parts. Shapeways achieves this unique finish for Nylon 12 [Versatile Plastic] Smooth with vapor smoothing techniques. With this post-processing method, rough surfaces that may be present after SLS 3D printing can be smoothed with chemical solvents as parts are placed into a sealed chamber filled with vapor.

Vapor smoothing chemicals cause a melting process which improves the surface and the performance of the part—including those with internal cavities—sealing in a soft shine. The Nylon 12 [Versatile Plastic] Smooth finish is watertight and suitable for use with functional 3D printed products as long as they do not have interlocking parts.

Nylon 12 [Versatile Plastic] – A 3D Printing Standard

3D printing was once a wild frontier of innovation, initially offering advanced but limited materials and technology in a futuristic, emerging industry. Quickly though, 3D printing exploded into a billion-dollar machine, bringing forth a new and exciting world for design and production; in fact, with 3D printing, parts could suddenly be produced through additive manufacturing that simply were not possible before.

With such an incredible buffet of choices available now, choosing the correct material can sometimes be the most difficult part of the process. Thermoplastics like Nylon 12 [Versatile Plastic] continue to play a starring role in the additive manufacturing realm whether for production of rapid prototypes or high-performance products. Suffice to say that this particular material is aptly named, with Nylon 12 [Versatile Plastic] surpassing a large volume of other 3D printing materials despite a wide range of selling points for most.

Recommended for a wide range of applications, there is a lot to know about Nylon 12. The overall appeal stems from excellent mechanical properties to include tensile strength, durability for long-term use, and resistance to abrasion, fatigue, and stress. And while the new White Smooth Versatile Plastic and Black Smooth Versatile Plastic offer the smoothest results yet, other very popular 3D printing finishes are available too—including Natural, Processed, and Premium.

Shapeways Customers Inspire with Nylon 12 for So Many Applications

Demonstrating the wide array of uses for Nylon 12 [Versatile Plastic] and all the choices in finish, Shapeways customers choose this material for 3D printing with Selective Laser Sintering (SLS) to make products like medical models, supplies, drones, luxury jewelry, and more—all taking advantages of the optional finishes.

3D Printed Medical Models

Uruguay-based Armor Bionics has channeled 3D printing into a technology capable not only of improving the quality of life for patients around the world, but saving lives too with their unique specialty: creating intricate 3D designs for medical models that are then 3D printed by Shapeways and used for diagnosis, training, and treatment. Armor Bionics CEO Bruno Demuro is dedicated to offering medical professionals better solutions for surgical planning:

“We’ve seen the benefits and how much treatment affects the patients,” said Demuro. “It betters the outcome of every single surgery where it is applied.”

3D Printing in Drone Technology

The aerospace industry leads in the use of 3D printed parts also, and has for decades—far before anyone even knew what the technology was about. Drone technology has taken off in recent years, with a special push via additive manufacturing—allowing engineers not only to create innovative designs but also use lightweight, durable materials with complex geometries. This is especially true for companies like Munich-based Quantum-Systems, specializing in advanced eVTOL (electric vertical take-off and landing) drones. Using 3D printing for prototyping and manufacturing of functional parts since their inception in 2015, Quantum Systems is able to make lightweight parts, while also taking advantage of ‘synergy effects’ in reducing part counts and assembly.

“Only because of the fact that we have integrated this manufacturing method into our manufacturing and development process, have we been able to significantly reduce development time. For injection molded parts, we save around 10 weeks by using 3D printed samples to release the CAD data,” said Florian Seibel, CEO of Quantum-Systems.

“The probability that these parts need a second loop of corrections is quite low in this way. For CNC-manufactured parts it is the same. We often just skip the first round of samples with 3D printed parts, which saves us three to four weeks. In general, I would say 3D printing saves us 20 to 50 percent of time, depending on which parts we design.”

3D Printing in Jewelry Applications

3D printing has a long history with jewelry makers too, and especially at Shapeways. Again, demonstrating the wide range of popularity amongst industrial designers, customers like Groen and Boothman continue to use Shapeways services for 3D printing luxury jewelry like their custom Creatures design series, featuring unique cuff bracelets. The designers rely on the lightweight quality of Nylon 12 [Versatile Plastic], along with the strength and durability of the material.

“3D printing gives us a chance to explore new avenues and get away from the mass production paradigm,” said Joanna Boothman.

Selective Laser Sintering with Nylon 12 [Versatile Plastic]

Selective Laser Sintering (SLS) is one of the originals in 3D printing technology, and remains one of the most powerful—especially with the ability to nest hundreds or even thousands of parts within any build. The average build size of an SLS 3D printer is around 300 x 300 x 300 mm with a layer thickness of 100 to 120 microns. Using materials like Nylon 12 [Versatile Plastic], the process begins as a thin layer of nylon powder is dispersed onto the build plate and then sintered layer by layer until the desired structure is complete.

Supports are not required in SLS 3D printing, and this means that designers are granted incredible freedom when creating 3D models because they don’t have to compensate for support structures. The lack of supports also makes the job of 3D printing engineers much easier at the other end as models can be nested easily within each print build and there is not the potential for damaging parts in post-processing with support removal.

Dyeing of 3D printed parts is possible too, along with choosing finishes and different options in post-processing for Nylon 12 [Versatile Plastic]. The material is naturally white but also available in the following hues: Black, Pink, Red, Orange, Yellow, Green, Blue, and Purple.

About Shapeways

Shapeways offers over 90 materials and finishes, and is always interested in sourcing other materials customers may be interested in using too. Contact Shapeways now to enjoy the benefits of advanced technology and materials for manufacturing creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders.Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Expanded Finishing Options for 3D Printing with Nylon 12 [Versatile Plastic] Smooth appeared first on Shapeways Blog.

• The manufacturing partnership between Shapeways and Armor Bionics.
• How 3D printed medical models are revolutionizing surgical planning.
• Why Armor Bionics delegates 3D printing to Shapeways.

When Pablo Pereira, co-founder and COO of Armor Bionics, saw his first 3D printer in 2008, he was mesmerized. Still busy attaining his engineering degree, Pereira had no inkling what a huge role the technology would play in his future years later. Even more important though was the role that Armor Bionics would play in helping surgeons offer patient-specific treatment and streamline surgeries around the world through the use of complex 3D printed medical models, further outlined in a downloadable case study here.

As fate would have it, Pereira happened to meet for coffee with industrial designer and entrepreneur Bruno Demuro, an old college buddy. Demuro, now the CEO of Armor Bionics, had been inspired during a personal experience. After his mother was diagnosed with breast cancer, she was admitted for surgery to remove a small tumor. When the surgeon informed Demuro that a sizable incision was needed for the removal of the tumor so he could get a full view, Demuro was not only alarmed, he decided there had to be a less invasive way to perform surgery. 

His mother survived the surgery successfully, but Demuro was inspired to find a way so that patients in the future would not have to face such risk. He began delving further into the idea of 3D design and medical models that would allow for in-depth diagnostics, training, and surgical planning. All of this played a large part in the coffee meeting between Demuro and Pereira as they engaged in an intensive conversation about the potential for 3D printing in medical applications. On the spot, the two came up with an exciting list of ideas, leading them to found Armor Bionics together shortly after.

Known now for their complex 3D printed medical models, Uruguay-based Armor Bionics started out with more of a bend toward prosthetics, prompting the visuals invoked by their name; however, the concept for  protecting and helping patients quickly evolved into a comprehensive surgical planning solution far beyond what anyone could have imagined just a decade ago.

Better Surgical Planning Benefits Everyone  

From 2015 on, Demuro and Pereira continued to hone their industrial design and engineering skills, along with 3D modeling. Rather than leaving skilled and very busy surgeons to navigate complex software, the team at Armor Bionics developed a system described by one experienced surgeon as a GPS for surgeries. Allowing doctors to plan and train for complicated surgeries, the Armor Bionics 3D printed models offer a stunning list of benefits that first and foremost, help patients experience better quality of care, quality of life, and overall better outcomes in surgery. 

Armor Bionics offers a fast and effective process for working with doctors and hospitals, beginning with finding out exactly what the requirements are for each surgery. Because human lives are involved, they are not afraid to create as many iterations as it takes to attain the detail and accuracy needed to plan a successful medical procedure using 3D printed models. And while they did delve into some 3D printing on-site too, Demuro and Pereira quickly discovered that mastering the technology is not as easy as it looks. These days, they delegate that work to the experts at Shapeways, sending the 3D designs over to the manufacturing team once they have been cleared for production. 

Demuro believes that all surgeons should have access to such progressive solutions:

“We’ve seen the benefits and how such treatment affects the patients,” said Demuro. “It betters the outcome of every single surgery where it is applied.”

The advantages for surgeons, hospitals, and even insurance companies are impossible to ignore. By providing incredibly detailed and accurate 3D printed medical models, Armor Bionics solutions help doctors shorten time in operating rooms, reduce recovery times for patients, and decrease the margin for error by providing more precise diagnostic and training tools. 

During each project, Armor Bionics consults extensively with the surgeons to understand the needs of the case and how their company can help. “We get involved. We want to better the outcome of each surgery,” says Demuro, explaining that the 3D designs they have sent to Shapeways for 3D printing have continued to act as an important resource in surgery.

With the ability to rehearse surgeries using 3D printed models that are the same size and shape as their patients’ organs, surgeons report feeling more confident in performing the actual surgeries. 

3D Printing is Meant to Assist Surgeons, Not Take Their Jobs

Often, there is the question of whether such technology only represents a veiled agenda to replace surgeons, and to continue diminishing the need for human resources in the future–another hot topic in areas like robotics. Demuro and Pereira are quick to dispel that idea, pointing out that their entire mission is to allow surgeons to spend more time helping their patients, and less time trying to figure out obtuse software or 3D modeling on the fly. Armor Bionics makes sure the extraneous work is already complete for doctors, along with vastly improving training for medical students who suddenly have access to plentiful, anatomically correct models.

Demuro and Pereira realize their talents lie in 3D modeling, and they are sticking to their strengths. That means reaching out to Shapeways for expertise in 3D printing that ultimately empowers surgeons and saves patients. Everyone is working on their core strengths, from Armor focusing on 3D modeling to Shapeways providing excellence in 3D printing, and surgeons performing the ultimate task in completing successful surgeries.

“We’re not trying to replace anyone,” says Pereira. “We are just adding one new tool to the surgical process, as a one-stop solution for offering a complete surgical planning unit.”

Demand is Increasing on All Levels for 3D Printed Medical Models

The popularity of Armor’s medical models has increased through word of mouth among doctors and patients. But while the future generations of younger surgeons are already familiar with the idea of 3D printing in surgical planning, it may take longer for widespread adoption to take place within the industry, explained Pereira.

“It’s not just the doctors, it’s not just the patients, it’s not just the hospitals spreading the word about these products,” said Pereira. “It’s also entire groups of patients, like mothers who need heart surgeries for their babies. They talk to each other, and as a result we have started to see a real community of patients who want the 3D models used in their surgeries, as well as doctors and hospitals that are impressed by the value of the services.”

For further details about the manufacturing partnership between Shapeways and Armor Bionics, download the full case study here.

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for manufacturing creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Armor Bionics: Better Surgical Outcomes with 3D Printed Medical Models appeared first on Shapeways Blog.

Strength and durability are two key benefits of PA11 that make this material ideal for functional parts like gears and hinges. High ductility is a major benefit too, offering excellent impact resistance for parts in applications like automotive or aerospace, as well as other manufactured parts that must hold up to rigorous use like protection equipment for sports. PA11 is also well-suited for applications that require resistance to harsh weather conditions, especially heat. 

Sustainable Origins: PA11 is Naturally Derived and Environmentally Friendly

Here’s an interesting fact about PA11 (also known as Nylon 11, EOS PA11, Nylon Polyamide 11), and one that many find surprising at first: it’s made from castor oil. The castor bean is actually an ingredient included in many different types of additives, from medical and skincare products to materials for industrial manufacturing. 

In terms of 3D printing, the eco-friendly PA11 can also be recycled easily in manufacturing—often up to 70 percent. This leads to one of the other greatest benefits not only for PA11 but SLS 3D printing overall. As one of the oldest, and still one of the most powerful forms of additive manufacturing, SLS 3D printing relies on a laser to move back and forth over each layer as a structure is built, sintering the nylon PA11 powder to build a solid structure. Supports are not necessary as the extra unsintered powder acts as a bolstering mechanism, surrounding and stabilizing the part during printing. Afterward, the powder can be reused.

Indisputable Advantages: Strength in Material Properties

PA11 possesses a wide range of strong material characteristics, making it conducive to additive manufacturing. These include:

• Tensile Strength – Measured in terms of how much stress a part can take before it breaks, tensile strength is often used to compare materials in durability for 3D printing. Force is measured in megapascals (MPa), which are units of pressure. With a high tensile strength like 48 MPa, and significant toughness, PA11 is a good candidate for sturdy, functional parts, as well as prototypes that will hold up over time. 
• High Elongation at Break  – Also known as ‘fracture strain,’ elongation at break measures a part after it has been fractured, comparing the initial length of the part and then the same after it has strained and broken. The goal is to assess how resistant the material is to stress or being stretched, as well as its flexibility, calculating the strain to failure mark in percentages. High elongation at break is an impressive feature of PA11 at 45 percent, as materials are ultimately able to bend and stretch out of their natural state while under stress and then return to normal afterward. With higher elongation at break comes higher ductility and impact resistance too.
• Elasticity – Good elasticity also allows a material like PA11 to return to its original state after being stretched or bent. Technically, elastic qualities refer to the energy left in a material after it has been placed under stress—allowing it to snap back into place. 
• Chemical Resistance – Superior resistance to chemicals like hydrocarbons, the primary elements of petroleum and natural gas, is a highly positive trait found in PA11 also—and often why this material is chosen for industrial applications. PA11 is also resistant to aldehydes, ketones, mineral bases, salts, alcohols, fuels, detergents, oils, and fats.

Exceptional Parts for Demanding Applications

While lending itself to extremely rigorous applications like automotive and aerospace, PA11 is biocompatible too, making it suitable for exterior medical applications, and especially those requiring not only the ability to hold up during long-term use but flexibility too. A good example would be 3D printed knee braces as well as other types of medical supports like prosthetics that offer progressive, patient-specific treatment due to the ability to customize devices, along with creating new ones quickly and affordably for patients like children who may continue to outgrow them. 

Upload your 3D models now to get started with printing in PA11 using industrial SLS technology from Shapeways.

The post PA11 3D Printed Parts are Built to Last appeared first on Shapeways Blog.

The possibilities in medical applications are endless too, illustrating what is undeniably now a critical aspect of 3D printing; after all, what could be more important than improving the quality of human lives—or saving them?

One of the most revered and most often discussed benefits of 3D printing is the ability to make strong yet lightweight parts and prototypes that simply were not possible before with conventional technology. This advantage is valuable to the medical industry because the impacts are so positive, so immense, and only just beginning.

The results of 3D printing are commonly so mind-boggling that the first descriptor brought to mind is “magical,” especially when considering the staggering potential in bioprinting. While the ultimate quest for so many researchers is in achieving the true 3D printing of human organs, there are already countless breakthroughs being made with 3D printed tissue—from the liver or kidney, as examples. Once that holy grail is reached it may not look anything like we once expected, but it is just a matter of time before highly functioning 3D printed organs are transplanted into human bodies.

In reality, there is no wizardry involved. Instead, it’s all about that perfect combination of advanced technology, advanced materials, innovation, and the tenacity required to make a difference. The secret to success lies in patient-specific treatment.

Medical models

The use of 3D printed medical models is multi-layered, and enormously useful. Not only do surgeons benefit by capturing a more detailed picture of rare conditions like brain tumors, but there are extremely valuable educational uses for everyone involved. While the doctor is able to diagnose and plot a course of treatment, they are also able to use a detailed visual aid to explain to the patient what is happening in the body, where, and how treatment and any possible surgery will be performed.

The value for being able to rely on medical models rather than waiting for the availability of cadavers is extraordinary. Realistic, anatomically correct 3D printed models act as advanced training aids for medical students overall, but especially future surgeons. Experienced surgeons may also find themselves training with 3D printed models for weeks at a time as they prepare for rare or completely new procedures. This type of pre-planning means more streamlined procedures, less time in the operating room, and great advantage to the patient.

Materials used for medical models

MultiJet Fusion PA12 – Suitable for the creation of complex medical models, this versatile material is strong and durable—both important characteristics for parts that tend to be handled a lot over time.

Prosthetics, orthotics & exterior devices

3D printing has made an enormous impact in applications like prosthetics, orthotics, and exterior devices like knee braces. In prosthetics especially, quality of life can be improved for patients who may not have been able to afford limb replacements previously or did not want to wear them due to self-consciousness. For children and individuals of all ages in developing countries, the ability to offer extremely affordable prosthetics that can be made fast is life-changing. These devices can be completely customized to the wearer, offering unprecedented comfort—and in many cases, better options for style too that encourage the patient to actually use their prosthetics.

Orthotics can be made affordably and quickly with completely customized fit. As with prosthetics for children, the ability to 3D print new devices easily is a huge advantage in terms of growth spurts. This is also a huge departure from the past when some devices may have been fitted using conventional technology, with the child outgrowing prosthetics or orthotics before they were even delivered.

Materials used for prosthetics, orthotics & exterior devices

Nylon 11 – Offering high tensile strength, durability, and impact resistance, this nylon plastic is used to 3D print exterior medical devices like braces—used with selective laser sintering (SLS).

Nylon 12 [Versatile Plastic] – commonly used for prosthetics with (SLS) 3D printing, this nylon plastic is both strong and flexible, and lives up to its name in offering high-performance for a wide range of products.

MJF Plastic PA12 – Used with multi jet fusion technology, strong mechanical properties, durability, and stiffness make this nylon plastic popular for 3D printing prosthetics and other complex structures.

MJF Plastic PA12 Glass Beads – Used with MJF for medical braces, this 40 percent glass-filled material is suitable for parts requiring excellence in dimensional accuracy as well as strength.

Surgical guides and tools

The use of 3D printed surgical guides and tools is again based around intensive customization, allowing for patient-specific treatment. Today, a wide array of guides and tools can be manufactured to streamline surgery, as well as dental procedures. The intent is to give the surgeon a comprehensive plan to follow during any procedure, whether performing hip replacements, knee replacements, dental surgeries, or other operations.

3D printed surgical tools may include items like clamps and grasping devices, retractors, hemostats, and handles and other supporting features. The ability to customize these designs offers huge advantages to surgeons who may need to modify tools depending on procedures or their own preferences.

Materials used for surgical guides and tools

Nylon 12 [Versatile Plastic] – Used with SLS technology to 3D print strong 3D printed surgical guides and tools, this material is very popular in a wide range of applications due to its ability to be flexible for thinner parts while stiff for thicker parts and prototypes.

Stainless Steel 316L – Suitable for surgical tools, this industrial metal is corrosion-resistant and extremely strong, used with binder jetting technology.

Multi-color 3D printing for complex models

For several years now, Shapeways has offered full-color prints via the Stratasys J750 printer. Casey Steffen of Biologic Models, for example, relies on complex 3D printed protein models and 3D medical animations for his business.

Using transparent plastic with the J750 allows for clear visualizations of the “delicate internal protein structures” Steffen and his customers must examine. 3D printing in color is also an extremely valuable tool for color coding models.

“With a color-coded model, an educator can easily explain how a certain drug functions, the property of the protein, or how mutation changes protein behavior by pointing directly to a color-coded spot,” said Steffen.

“Color 3D-printed protein models paint a more vibrant picture of an otherwise invisible molecular universe. Transparency and color coding are necessary features to create high quality, durable models.”

“Thanks to the J750, I will be able to print multi-colored transparent scientific models while completely eliminating a costly and time-consuming fabrication and assembly process. It’s a game changer for me and my customers,” said Steffen.

Voytek partners with Shapeways to 3D print medical cable organizers

Most patients leave the hospital or a busy doctor’s office with a vision of medical equipment and cords and cables snaking everywhere. With an obvious need for better organization, Voytek Medical began working with Shapeways to 3D print products for locking in patient cables to protect medical equipment usually attached to monitors or roll stands.

Voytek was able to try out new products for their line, and affordably so, allowing them to grow at their own pace and settle on the best materials for the specific needs of their customers.

“Voytek Medical has been using Shapeways in every stage of production, from concept to prototype and end-user products,” said the Voytek team.

“In the trial-and-error phase of our designing, the use of extrusion desktop 3D printing in ABS was the best option available to us at the time. This material was far from precise, very brittle, and the layers tended to separate over time. From that point, stereolithography was used that brought us into the world of really designing with a purpose and good quality.”

Medical 3D printing requires advanced tools

If you look back over the previous few decades, materials have not changed all that much, from thermoplastics to metal. The ways in which they are used has changed immensely though—whether in manufacturing 3D printed models or devices like prosthetics, implants, or molds. 3D printing means combining advanced materials with advanced technology for manufacturing high-performance parts at an accelerated rate.

Shapeways offers over 10 different technologies for manufacturing, and 90 different materials and finishes. Find out more about what is available at Shapeways for 3D printing customized medical models, devices, and tools here. Upload up to 20 models at a time, receive instant quotes—and look forward to consistent, quality products every single time.

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