Development of Human Bone Implant using FDM Based Printer from CT Scan Data

The project is based on the additive manufacturing techniques to manufacture custom bone implants for patients. Most commonly metal implants are being used in the medical field. Metal is not biocompatible and can have severe side-effects. Many patients face infections and implant rejections after th

Project Title

Development of Human Bone Implant using FDM Based Printer from CT Scan Data

Project Area of Specialization

Mechanical Engineering

Project Summary

The project is based on the additive manufacturing techniques to manufacture custom bone implants for patients. Most commonly metal implants are being used in the medical field. Metal is not biocompatible and can have severe side-effects. Many patients face infections and implant rejections after the surgery.

In our country there is negligible availability of custom made bio-compatible bone implants. Our project will help us figure out the needs and the knowledge for understanding the whole process of 3D printing and designing of above mentioned bone implants.

Project Objectives

The main objective of our project is to provide custo built bio-compatible bone implants to every patient who is in need. 

Our second objective is to familarize the Pakistani's with the benefits of 3D printed objects.

Third objective is to revolutionize the medical industry and make wa for 3D printed implants rather than the typical metallic ones.

Project Implementation Method

Firstly, Computer tomography (CT) and Magnetic resonance imaging (MRI) will be used to obtained data of the individual patient and then converted into 3D CAD data by using different software in standard triangulate language (STL) format. These models would aid in the development of patient specific bone implants, in collaboration with experienced surgeons.

Secondly, by modifying the existing FDM 3D printers to accommodate the use of PEEK material, these unique bone implants would be printed out. This technology easily fulfills various challenges as compared to the traditional manufacturing method. Also, PEEK is used in 3D printing for manufacturing of complex design implants which is readily acceptable by the human body

Lastly, these 3D printed PEEK implants will be further tested extensively using several devices which would help in improving the bone implant model.  The implementation of 3D printed model for surgery of patients and required clinical applications would be conducted through the efforts of qualified surgeons in Pakistan.

Benefits of the Project

The rapid casting via FDM has been successfully applied for medical applications to manufacture geometrically complicated physical prototypes of human anatomy derived from scanned data. The process could accelerate the production of patient specific implants within lower costs and time. The image of defected bone retrieved from computerized tomography or magnetic resonance imaging can be transferred into 3D model which can be fabricated as replicas, and finally highly precise casting can be prepared.

Our project will allow us to create custom design implants for each patient as no person has the saem bone structure as another one. Custom desgining the bone implants will be very beneficial for the patient.

3D printed implants are way more bio-compatible than the metallic bone implants. By printing such implants we can save the patients from various infections caused by the metallic implants. 

Metallic implants can also cause internal injury whereas 3D printed implant do not have such effects.

There is no other organization in Pakistan which is 3D printing custom implants. Our project can influence the medical field for good.

Technical Details of Final Deliverable

As per existing research, PEEK implants through Additive Manufacturing techniques, do not introduce any new issues of safety and effectiveness that do not already apply to traditional manufactured PEEK implant. Also, Medical data is varying from patient to patient, so there is a requirement of customization. Additive manufacturing will help easily create customized implant as per patient match in less time as contrast to conventional methods. PEEK 3D printed implants provide higher design freedom with a lesser waste of raw material. These implants reduce the failure rate of the patient and are bone-friendly.
In terms of health, PEEK implants are biocompatible and durable. It is the best material for pivotal applications, such as orthopedic implants, spinal implant, surgical equipment, and dental equipment. These materials are tough having the capability to withstand high temperatures. It creates innovation for spinal arthroplasty devices. PEEK is used for reconstruction of the customized face of the individual patient with a required strength, durability and stiffness. It can therefore replace titanium and ceramic implants which are not only incompatible with the human body but also are far expensive than PEEK. In addition, Additive manufacturing techniques would allow us to create highly detailed textures on the surface of implant which will allow surrounding tissue to adhere to it.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Medical

Other Industries

Core Technology

3D/4D Printing

Other Technologies

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com