Research J. Pharm. and Tech. 1(4): Oct.-Dec.

2008, ,

ISSN 0974-3618
REVIEW ARTICLE

www.rjptonl ine.org

Rapid Prototy pe Techniq ue in Medical Field

Nagarjan Tukuru*, Shivalinge Gowda KP, Syed Mansoor Ahmed and S Badami
S r e e S i d d a g a n g a n g a C o l l e g e o f

P h a r m a c y , T u m k u r 5 7 2 1 0 2 * C o r r e s p o n d i n g A u t h o r

2. RP INTRODUCTION: TECHNIQUES M Rapid prototyping is the: automatic construction ofThere a are i physical objects using solidcurrently a freeform fabrication. Thenumberl of RP first technique for rapidtechnologies on : prototyping becamethe market, available in the late 1980sbased on special n and was used to producesintering, a models and prototypelayering or g parts. Rapid prototypingdeposition takes virtual designs frommethods p as Computer Aided Designdescribed h (CAD) or animationbelow. a
modeling software, r transforms them into thin, m virtual, horizontal crosssections and then creates a each cross-section in 7 physical space, one after @ the next until the model is g finished. However, each m rapid prototyping platform a uses the same principles of slicing, layering and i bonding to build parts. l Several research . institutions and c commercial organizations o have integrated Computeraided Design (CAD) and m Rapid Prototyping (RP) systems with ABSTRACT: medical imaging systems Rapid Prototype is to an innovative fabricate medical has evolved within the technology that devices or generate 3D hard copy industries. In design and manufacturing of these objects for usethe use of RP in medical industries surgical rehearsal, custom technology coupled with the other implant design and casting.improvement in techniques has led to In manufacturing, models patients services offered to by are planned and in such areas as 3D improvement conceived entirely on theofcomputer visualization a specific anatomy, screen, then converted to surgical planning, implant design, physical reality. In bio- polymeric drug prosthesis production, and medical devices. In this article we review delivery applications, the objects normally already the current technologies available in RPT exist its application in different fields of and physically. Prior to building, and future highly in this area. medicine this trends complex data needs extensive pre-processing to KEY WORDS: Rapid prototyping (RP), provide aaided design (CAD), medical computer format that a CAD program can applications modeling process, utilize, before transferring to an RP system.

Received on 15.01.2009 Modified on 16.01.2009 Accepted on 17.01.2009 RJPT All right reserved
Research J. Pharm. and Tech. 1(4): Oct.-Dec. 2008; Page 341-344

2.1. Stereo lithography (SLA):

Patented in 1986, this is the laser sintering leading technology, with (SLS): over 500 SLA machines This technology installed worldwide, was developed developed by 3-D Systems by Carl Deckard Inc, of Valencia, CA. for his masters Stereo lithography creates thesis at the 3-D models out of acryl ateUniversity of photopolymer or epoxyTexas, patented resin, by tracing a low-in 1989 and powered ultraviolet lasercommercialized across a vat filled withby DTM Co, of resin. Austin, TX. SLS

2.2. Selective

The material is cured bymodels out of a the laser to create a solidheat-fusible thin slice. The solid layer powder, such as is then lowered just below polycarbonate or the surface and the next glass-filled slice formed on top of it, composite nylon, until the object is by tracing a completed1-3. It ismodulated laser regarded as a benchmark beam across a by which otherbin covered with technologies are judged.the powder. A recent development byHeating the Zeneca is a translucent particles causes resin which changes tothem to fuse or red when acted upon by sinter together to higher laser energy. Thiscreate a solid can be used to display thin slice. The local regions of interest, solid layer is and an obviousthen covered by application would be formore powder and the surgeon to draw round the next slice a tumor on the medical formed on top of image slices and have it it, until the to build into the model.
object is completed. The same process can be performed with

creates

3-D

341

Research J. Pharm. and Tech. 1(4): Oct.-Dec. 2008, ,

a combination oflayer to be built. This low-carbon steelphotomask is printed on a glass plate above the and thermoplastic build platform using an binder powder,electrostatic process resulting in asimilar to that found in 'green state' part.photocopiers. The mask is The binder isthen exposed to UV light, then burned offwhich only passes in a furnace andthrough the transparent the steel particlesportions of the mask to are allowed toselectively harden the sinter together4.shape of the current layer. The resultingAfter the layer is cured, steel skeleton isthe machine vacuums up subsequently the excess liquid resin and infiltrated withsprays wax in its place to copper, resultingsupport the model during in a metal-the build. The top surface composite part.is milled flat, and then the A similarprocess repeats to build technology isthe next layer. When the also used by EOSpart is complete, it must GmbH, ofbe de-waxed by Planegg, immersing it in a solvent Germany, whichbath. SGC machines are can fabricatedistributed in the U.S. by metal parts out ofCubital America Inc. of bronze alloyTroy, MI. The machines powder that canare quite big and can be sintered into aproduce large models. solid mass. 2.4. Fused deposition 2.3. Solid modeling (FDM): Ground Curing This technology was (SGC): developed by Stratasys Inc,

Developed byof Eden Prairie, MN. FDM Cubital, solidcreates 3-D models out of ground curingheated thermoplastic (SGC) ismaterial, extruded through a somewhat similarnozzle positioned over a to computer-controlled x-y stereolithography table. The table is moved to (SLA) in that both accept the material until a use ultraviolet single thin slice is formed. light to selectively The next slice is built on top harden of it until the object is photosensitive completed. FDM utilizes a polymers. Unlike variety of build materials, SLA, SGC cures such as polycarbonate, an entire layer at a polypropylene and various time. It is also polyesters which are more known as the robust than the SLA Solider process. models. A similar approach First, is used by Sanders photosensitive Prototype Inc, of Wilton, resin is sprayed on NH, to produce 3-D models the build platform. by extruding thermoplastic Next, the machine material through ink-jet develops a printer nozzles. FDM photomask (like a models can also be made in stencil) of the
wax, enabling custom-made

implants to bewalled sections. After investment cast forthe first layer is cut, the individual patients. platform lowers out of

the way and fresh material is advanced. 2.5. Laminated The platform rises object slightly below the manufacturing previous height, the (LOM): roller bonds the second In this technique,layer to the first, and the developed bylaser cuts the second Helisys oflayer. This process is Torrance, CA,repeated as needed to layers ofbuild the part, which adhesive-coated will have a wood-like sheet material aretexture. Although these bonded together tomodels are robust, it is form a prototype.difficult to remove The originalunwanted regions of material consistspaper from areas of of paper laminatedcomplex geometry.

with heatactivated glue and2.6. 3-D printing: rolled up onThis technology was spools. Adeveloped at MIT and is feeder/collector being commercialized mechanism by a number of advances the sheetcompanies. 3-D printing over the buildcreates models by platform, where aspraying liquid through base has beenink- jet printer nozzles constructed fromon to a layer of metallic paper and double-or ceramic precursor sided foam tape.powder, thus creating a Next, a heatedsolid thin slice. The roller appliesprinting process is pressure to bondrepeated for each the paper to thesubsequent slice until base. A focusedthe object is completed laser cuts theas a 'green-state' part. outline of the firstThe part is then fired in layer into thea furnace to sinter the paper and then powder. The resulting cross-hatches the skeleton object is excess area (the subsequently infiltrated negative space in with metal, resulting in a the prototype). full-density part. This Cross-hatching process is very fast and breaks up the produces parts with a extra material, slightly grainy surface. making it easier to Machines with 4 color remove during printing capability are post-processing. available. During the build, the excess 2.7. Multiphase jet material provides solidification (MJS): excellent support This technology was for overhangs and developed by the thin-

network of Fraunhofer Institutes in Germany. MJS creates 3-D metal or ceramic models out, of various low-viscosity

materials inImaging (MRI). CT and powder or pelletMRI represent the finest capability form, byresolution extruding theavailable in diagnostic achieving build materialsystems resolutions. through a jet involumetric liquid form. EachDuring the scanning layer that isprocess, the patient is stepped through the deposited measurement plane 2solidifies on to the previous one,3mm at a time. The until the entireinformation from each object is created.plane can be put together This technology to provide a volumetric is still in theimage of the structure as well as the size and development location of anatomical phase.
structures. The scanned model becomes a virtual 3. FABRICATION volume that resides in a representing OF MEDICAL computer, the real volumes of the MODELS: The medicalpatients bone(s). The volume is modeling processvirtual displayed on-screen by is broadly split into three areas,reformatting the data to orthographic 1) Datacreate projections, or by a acquisition, 2) creating a pseudo 3D Image using processing, andrepresentation 3) Modelsurface-rendering algorithms6, 7. production.

3.1. Data Acquisition:

In imaging, the twoWhen a series of CT most commonimages is reassembled to a 3D systems used inillustrate presentation of an acquiring detailed anatomic structure, the anatomical information aremedical practitioner or prosthetic designer can Computed use this information Tomography (CT), anddirectly and the overall shape of body structures Magnetic is more clearly Resonance

3.2. Data reconstruction/Processi medicalng:

342

Research J. Pharm. and Tech. 1(4): Oct.-Dec. 2008, ,

understood orchecking possible errors visualized. Thisor other important steps process requires awhich depends on the good visualizationconcrete case. software packages. These3.4. RP Medical Model software packagesValidation: take anatomicalWhen the RP medical data from CT andmodel is manufactured it MRI scans andshould be validated by create computersurgeons. If there are no models oferrors the model is ready anatomical for application.The structures. A userMaterialize package has can modify thetwo modules: MIMICS image by definingand CTM suites. various tissue densities for 1) Mimics: Mimic display. This is a software allows separation suite that of data of interest performs the from the general segmentation of information the anatomy available from the through scanner. By sophisticated combining the threedata generated dimensional with a traditional selection and CAD system, editing tools. design of new The program parts can be also generates undertaken by high-resolution comparison with 3D renderings the reconstructed in different 3-D anatomical shape. When colors directly segmentation and from the slice visualization is information as completed the shown in fig-1. data can be After translated into visualization, instructions for the data can be manufacture of interfaced to parts often by CTM. RP6.

3.3. Evaluation of Design: This step depends on a case-to-case basis. Sometimes the created model is directly used as an input for RP machine (biomodels). This is necessary for evaluation of design, quality of the made model,

2) CTM: CTM is a software suite that interpolates the medical slice in very thin layers, and interfaces directly with most RP systems. Because of this direct interface and the use of higher-order interpolation mathematical

algorith 62. Great ms such improvements as to the fields of Bilinear prosthetics and and Cimplantation: Spline RP techniques are very function useful in making s, itprostheses and implants produce for years. The ability to s veryquickly fit prosthesis to accurate a patient's unique models proportions is a great in a veryadvantage. The short techniques are also used time. Afor making hip sockets, resolutio knee joints and spinal n implants for quite some enhance time. Both the release of ment and the improvement of techniqu the properties of used e ismaterials have had a necessar significant influence on y whenthe quality of prostheses creating and implants made by the RPRP. One interesting models example is so as to minimiz e the effect of stairstepping , and to retain the natural curvatur e of the surface. 6. APPLICATION S: 61. Design and develop ment of medical devices and instrum entation :
This is the field where applications of RP show the best results. It specially applies to hearing aids but also to other surgical aid tools8.

maxillofacial and explaining complex prostheses of ansurgical operations: ear which isThis is very important obtained byrole of RP technologies creating a waxin medicine which cast by laserenable presurgery sintering of aplanning. The use of 3D plaster cast ofmedical models helps existing ear. Duethe surgeon to plan and complex to RPperform surgical procedures and technologies it is very easy tosimulations and gives him an opportunity to manufacture custom implants.study the bony structures The made modelof the patient before the could be used as asurgery, to increase negative or asurgical precision, to reduce time of master model of procedures and risk the custom during surgery as well as implant. Many costs (thus making researchers surgery more efficient). explored new The possibility to mark applications of RPdifferent structures in in this field9, 10.

different colors (due to segmentation technique) Fig- 1: in a 3D physical model Flowchart can be very useful for diagram on the surgery planning and better understanding of conversion of scanned data to the problem as well as for teaching purpose. physical 3D This is especially model important in cancer surgery where tumor tissue can be clearly distinguished from healthy tissue by different color 11, 12. Surgical planning is most often done with stereolithography (SLA) where the made model has high accuracy, transparency but limited number of colors and 3DP (for more colored models, presentation of FEA results). 6.4. Teaching purposes: RP models can be used as teaching aids for students in the classroom as well as for researchers. These models can be made in many colors and provide a better illustration of

6.3. Planning

343

Research J. Pharm. and Tech. 1(4): Oct.-Dec. 2008, ,

anatomy, allowor birth. FDM, SLS and viewing of3DP can be used to internal fabricate a functional structures andscaffold directly but RP much bettersystems can also be used understanding offor manufacturing a some problems sacrificial mould to or proceduresfabricate tissuewhich should be engineering scaffolds14. taken in concrete case13. They are7. RECENT AND also used asFUTURE TRENDS: teaching Recently this technique simulators. was used for the separation of Siamese 6.5. Design and twins who was borned manufacturing by the attaching of the biocompatible skull portion as shown and bioactive below. implants and tissue Engineering:
RP technologies gave significant contribution in the field of tissue engineering through the use of biomaterials including the It is a very significant direct manufacture ofdiscovery in medicine and the first step on the bioactive implants. Tissueway to making other engineering is acomplex human organs. combination ofFurther development in living cells and aRP in tissue engineering support structurerequires the design of called scaffolds.new materials, optimal RP systems likescaffold design and the fused depositioninput of such kind of modeling (FDM),knowledge of cell 3D printing (3-physiology that would DP) and selectivemake it possible in the laser sinteringfuture to print whole (SLS) have beenreplacement organs or proved to bewhole bodies by convenient formachines. There are also making porousmany new trends of structures for useapplying RP in in tissueorthopedics, oral and engineering. Inmaxillofacial surgery this field it isand other fields of essential to bemedicine. able to fabricate three-dimensional 8. CONCLUSION: scaffolds ofRP technology can make various geometricsignificant impact in the shapes, in order tofield of biomedical repair defectsengineering and surgery. caused byPhysical models enable accidents, surgery,

correct Surgical procedures identification ofcontinue to be more bone abnormality,effective day by day with intuitive reduced risk and expense understanding ofto both the patient and the the anatomicalhospital. This could help issues for aminimize the problem of surgeon, implantlong waiting list and designers andcongestion in big patients as well. Ahospitals by reducing precise RP modelreferral cases. facilitates the preoperative planningREFERENCES: of am optimal1. Jacobs P et al. surgical approach Stereolithography and other RP & M and enables technologies from selection of Rapid prototyping to correct or Rapid tooling. ASME appropriate press, 1995. TM ofmed 2. Barker16: 79-85.to al. Integration et 3D medical imaging and Eng Scirapid prototyping Aust create stereolithographic models. Phys 1993; implants. In the 3. Mankovich NJ et UK, RPT has been al. The display of used to help plan three-dimensional treatment in more anatomy with stereolithiographi than 20 patients; c models. The however, the cost digital imaging of the modeling 1990; 3: 200-03. process is 4. Milovanovic J et currently a al. 2005, significant Possibilities of limitation to its using selective use. laser melting for
tire mold manufacturing, Proceedings. Second international Conference on Manufacturing Engineering Icmen, Kallithea of Chalkidiki, Greece. 2005; 187-93. Pommert JK et al. Three dimensional imaging in medicine: method and applications, in computer integrated surgery. 1996; 9: 155-74. Udupa JK et al. Imaging transforms for volume visualization, in computer integrated surgery. 1996; 3: 33-57. Swalens B et al. Medical Application of Rapid

5.

6.

7.

Prototypi ng Techniqu es. Fourth Internatio nal conferenc e on Rapid Prototypi ng, 1993; 107-20. 8. Bibb R. Medical modeling The applicatio n of advanced design and developm ent technique s in medicine. Universit y of Wales, UK. 2006; 312. 9. Fergal J et al. Bone as a composit e materialThe role of osteons as barriers.t o crack growth in compact bone. Internatio nal Journal of Fatigue 29, 2007; 105156. 10. Woesz A et al. Towards bone replacem ent materials

11.

12.

13.

14.

from calcium phosphates via rapid prototyping and ceramic gel casting. Materials Science & Engineering Cpp. 2005; 25: 187-93. Robiony M et al. Virtual Reality Surgical Planning for Maxillofacial Distraction OsteogenesisThe Role of Reverse Engineering Rapid Prototyping and Cooperative Work. Journal of Oral and Maxillofacial Surgery, 2007; 1198-08. Winder J et al. Medical Rapid Prototyping TechnologiesState of the Art and Current Limitations for Application in Oral and Maxillofacial Surgery. Journal of Oral and Maxillofacial Surgery, 2005; 1006-15. Gibson I et al. The use of rapid prototyping to assist medical applications. Rapid Prototyping Journal, 2006; 12: 5358. Gibson I. Advanced Manufacturing Technology for Medical ApplicationsReverse Engineering, Software Conversion and Rapid Prototyping. Wiley, 2006; 254.

344 PDF to Word