Production Technology for Additive Manufacturing

Electron Beam Melted (EBM) Ti-based medical implants

or

How implant manufacturers use Additive Manufacturing to reduce production costs and increase profits
2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Arcam

Swedish innovation from the beginning of the 1990s Arcam AB incorporated 1997 Listed on Nordic Growth Market

Main owner (25%) Industrifonden (Industrial capital trust)

Turnover 10.1 M (2010) First EBM system delivered in 2003 About 70 systems installed worldwide 50 people, in Sweden, the U.S., Italy and China Sales partners in Europe and Asia

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Additive Manufacturing

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Electron Beam Melting (EBM)

A high energy beam (up to 3.000 W) is generated in the electron beam gun The beam melts each layer of metal powder to the desired geometry The high beam power gives high build rate (up to 80 cm3/h) and productivity Extremely fast beam translation with no moving parts Vacuum process eliminates impurities and yields excellent material properties High process temperature (700 C for titanium) gives low residual stress > no need for heat treatment Low operating costs

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Medical Implants

Overview Applications

Medical Implants Aerospace

Arcam Products Materials

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

EBM - Core Benefits

Freedom in design Excellent material properties Cost-efficient production

And, for implant manufacturing

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Trabecular Structures

Design your trademark trabecular structure in CAD Optimize for osseointegration

Pore geometry (no limitation) Pore size (down to ~400 m) Porosity (up to ~85%)

Competitive manufacturing costs

EBM production cost, typical: < 2 / cm3 trabecular structure

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Bio-Compatibility

Pictures of bone growing into EBM-manufactured titanium implants with Trabecular Structures
Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials, University of Gothenburg.

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Implant Categories

Acetabular cups Revision cups Augments Femoral stems CMF Spine Shoulders Triflanges Tibial trays Femoral knees

In production with EBM

2011-12-13

INNOVMAT Smolenice, SK

Production Technology for Additive Manufacturing

Production Benefits

Single-step production of solid and porous sections, with structural continuity between them All-porous implants possible (augments, wedges, ) No secondary high temperature process to apply the porous structure that could cause grain growth High process temperature gives low residual stress, and no need for heat treatment after the build

2011-12-13

INNOVMAT Smolenice, SK

10

Production Technology for Additive Manufacturing

Cost Savings with EBM

The additional cost for applying a porous coating on an acetabular cup can be anything from 30 to 60 per cup

With EBM you produce the cups with an integrated porous structure, which eliminates this cost

When producing acetabular cups from bar, 60-70% of the stock material is typically machined away

With EBM you only use the material needed to produce the cups. The remaining powder is recycled and reused

2011-12-13

INNOVMAT Smolenice, SK

11

Production Technology for Additive Manufacturing

EBM Production Cost, typical

Additive Manufacturing of Ti6Al4V acetabular cups with integrated trabecular structures
Cup size Weight cup, build (g) Build time / batch (h) Batches per week Cups per batch Production cost / cup ()

44 46 48 50 52 54 56 58 60 62 64 66

71 79 87 95 104 113 123 133 143 154 165 176

10 10 10 10 10 11 11 11 11 12 12 12

14 14 14 14 14 14 13 13 13 12 12 12

16 16 13 12 12 10 10 9 9 9 9 7

40 42 49 54 56 65 69 76 78 83 86 103

Includes costs for EBM system, material, Support & Maintenance agreement and operator

2011-12-13

INNOVMAT Smolenice, SK

12

Production Technology for Additive Manufacturing

CE-certified Implants since 2007

CE-certified acetabular cups with integrated, engineered Trabecular Structures since 2007 Implants with FDA clearance since 2010 > 40,000 cups manufactured > 20,000 cups implanted

Adler Ortho, IT 2007

2011-12-13

Lima-Lto, IT 2007
INNOVMAT Smolenice, SK

Exactech, US 2010
13

Production Technology for Additive Manufacturing

Summary

EBM lets you design and produce unique trademark Trabecular Structures with minimum investment EBM offers a unique single-step production method for solid and porous implants EBM provides structural continuity between solid and porous sections, and requires no heat treatment EBM is a proven and cost-efficient technology, with thousands of implanted CE-approved products

2011-12-13

INNOVMAT Smolenice, SK

14

Production Technology for Additive Manufacturing

Aerospace

Overview Applications

Medical Implants Aerospace

Arcam Products Materials

2011-12-13

INNOVMAT Smolenice, SK

15

Production Technology for Additive Manufacturing

Turbine Blades
Material: Size: Weight: Build time: -TiAl 8 x 12 x 325 mm 0,5 kg 7 hours / blade

For stages 6 and 7 in the low pressure turbine in General Electrics GEnx aero engine, where the TiAl (~4 g/cm3) replaces blades made in heavier (>8 g/cm3) nickel-based superalloys
2011-12-13

INNOVMAT Smolenice, SK

16

Production Technology for Additive Manufacturing

Contact

Thank you for your attention!

Arcam AB Kroksltts Fabriker 27A SE-431 37 Mlndal, Sweden Phone: +46 31 710 32 00 Web site: http://www.arcam.com E-mail: info@arcam.com

Arcam - Manufacturing Revolutionized

2011-12-13

INNOVMAT Smolenice, SK

17