Rapid Prototyping for the Medical Industry

I recently visited a medical device manufacturer. They are currently using a photopolymer rapid prototyping machine. Now, I will admit, the photopolymer material is impressive. It can print some very nice looking parts. But it does have its short comings. The main problems are that the materials have a very short shelf-life, are non-functional, can be hard to maintain, and cannot withstand heat over 110° F.

Photopolymer material, by nature, is sensitive to light, heat, and moisture. My source at this particular manufacturer shared with me that some of the parts were even sensitive to the heat coming from his hand! All of these factors easily degrade the geometry of the parts you build. Due to the gradual degradation of these parts, it makes it impossible to use them for any practical real world purpose other than a simple "show piece" or short-term option.

These photopolymer machines are also difficult to maintain. When you print a part it generally leaves a lot of waste behind. Photopolymer material is also toxic until it is cured. This extra material that is left behind is still in its uncured state. Which means material that you cannot use and must be disposed of will have to go through a curing process just to be discarded!

The solution I offered to this manufacturer was our Stratasys Fortus 400mc. This machine runs eight different types of thermoplastics that build REAL, stable and functional parts. Three of the eight materials can be autoclaved. The fact that these parts can be autoclaved makes it possible to bring these parts right into the operating room. The advantage of building functional parts is that body and organ models can be built to help surgeons "practice" very complex surgical procedures before having to perform them on patients, lowering the risk of complications during or after surgery.

Parts built in the Fortus 400mc can also be used in prosthetics. When surgeons attempt to replace, or join back together broken bone, they typically use titanium mesh prior to osteointegration. In many cases this titanium mesh is fitted incorrectly and later causes discomfort in patients requiring them to go through physical therapy. With parts printed in the 400mc, a replica of the patients bones (using CAD software) can be printed, and the mesh can be fitted prior to the surgery. This eliminates the risk of the patient having complications after the surgery is done.

With the Fortus 400mc, you can build parts that can be used in the operating room. The parts have a very high tolerance for heat, light, and moisture. It is the logical choice if you are looking for a more efficient way to work with patients with both small and large medical problems.