
Medical Production: EMD Millipore’s Muse Cell Analyzer
EMD Millipore utilized urethane casting for initial product launch.EMD Millipore utilized urethane casting for initial product launch.
Read the Case Study3D Printed Bone Model
Sonoma Orthopedics Products, Inc. has been pioneering technologies to facilitate the use of intramedullary devices for ankle, wrist and clavicle fracture repair, bones that have historically been too small to allow for this type of procedure. Their intramedullary fracture repair products involve a proprietary pin technique. After drilling into the bone and aligning the pin with a guide, Sonoma’s intramedullary pin releases fixation grippers in place of screws. The fixation grippers are located within the bone on the far end of the pin, and complemented with additional external screws on the near end. The combination thoroughly aligns and immobilizes the fracture to guarantee proper bone alignment. As this procedure becomes more commonplace, training doctors and surgeons on proper techniques to further decrease recovery time and increase patient quality of life is critical. To train doctors on advanced intramedullary fracture repair procedures, Sonoma Orthopedics wanted to create a model that mimicked bone, accurately recreated delicate fracture variations, and allowed surgeons to use Sonoma’s pins on the model during training.
The ability of 3D printing to quickly and accurately reproduce a model directly from computer data makes it an ideal alternative to cadaver or foam bone models for Sonoma. 3D printed bone models provide quality-controlled fractures that actualize important nuances in fracture details from body to body. 3D printed bone models are also printed on-demand to reflect a specific patient’s fracture in order to prepare doctors for more challenging or complicated surgeries.
In order to prepare for the most likely fracture scenarios, Sonoma references an expansive CT-scan library. Sonoma works with the CT-scan library to form accurate representations of 20-50% average bone size and fracture configurations which are then 3D printed as models for training. Using this method, doctors are able to practice with the best average and learn how to heal the most common fractures and abnormalities.
“Sonoma Orthopedic Products partners with Stratasys Direct Manufacturing frequently because 3D printing builds models of fractures and canals that not only demonstrate our surgical device but actually teach surgeons, ‘Here’s how to insert our screw into the bone, here’s how to really use it,” says McDaniel. “We would not get the same quality we get with 3D printing in three days via conventional means.”
“We call the model Bigfoot. Bigfoot works like a tractor beam, attracting surgeons to our booth.”
3D printing provides an ideal low volume production solution for end-use training models, but it is also Sonoma Orthopedics’ go-to for proof-of-concept prototyping and material experimentations. “With 3D printing, I’m able to send a model to Stratasys Direct Manufacturing and have it in-hand within days and that allows me to perform a new test so much faster,” says McDaniel. “We don’t have these kinds of prototyping capabilities in-house, so having this ability in 3 days versus the six weeks it would normally take with conventional means makes our iterative design process much faster. I’m able to simply take the CT-scan and our intramedullary instrument and hold up the bone model and determine whether or not it’s the right fit.”
Sonoma relies on multiple 3D printing technologies for models, prototyping and even marketing collateral. Pictured below is a large scale model of a particular ankle fracture with Sonoma’s intramedullary device in place. Stereolithography is an ideal technology for large, lightweight parts with finer feature details thanks to its ability to print fine layers quickly and in a build volume of 20x20x20”.
“Our 3D printed large scale model features fractures expanded to show the application of the screws and to show how the fracture is repaired,” explains McDaniel. “We call the model Bigfoot. Bigfoot works like a tractor beam, attracting surgeons to our booth.”
EMD Millipore utilized urethane casting for initial product launch.
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