Additive Manufacturing for Medical Applications. Ed Littlewood Marketing manager, medical and dental products

Transcription

1 Additive Manufacturing for Medical Applications Ed Littlewood Marketing manager, medical and dental products

2 Agenda Renishaw introduction Business model innovation A new way of developing and supplying AM solutions Optimising AM systems Our AM journey so far

3 About Renishaw World leading metrology company A FTSE 250 company with headquarters in United Kingdom Advancing operational performance Transforming manufacturing efficiencies and raising product quality Maximising research capabilities Improving medical procedures and patient outcomes

4 Highlights 356 million sales in % of revenue spent on engineering, including R&D in countries with local subsidiary offices employees (at Dec 2014)

5 Our customers Aerospace Agriculture Automotive Consumer products Marine Construction Medical Power generation Quarrying and mining Oil and Gas

6 Our expertise Healthcare Stereotactic neurological systems Medical dental Raman spectroscopy Diagnostics

7 BUSINESS MODEL INNOVATION

8 Business model the components We sell.. scanners and CAD systems that enable... the sale of frameworks.

9 Business model supplying dental technology Dentist Lab Renishaw Impression STL Restoration Frameworks

10 Business model innovation introducing metal AM 2009 Market demands low cost alternative to zirconia Metal frameworks are most requested new consumable Financial crisis drives business model innovation

11 Business model innovation metal AM grows 2010 Metal frameworks become a major growth area Submissions grow faster than any other consumable

12 Business model innovation new components Now we also sell.. additive manufacturing systems.. and powders Renishaw acquire MTT

13 A new way of developing and supplying AM solutions HEALTHCARE

14 Offer credible solution Understand the specific healthcare markets and their drivers, financial, legal and regulatory Uncover the issues facing our customers in their production environment Develop new and existing processes to complement AM Optimise additive manufacturing systems to get the best out of them

15 Feel the pain.. Assess market opportunities Understand and even supply the inputs i.e. industry specific CAD systems Understand associated technical, production and operational issues Produce solutions Set-up full, regulated and quality assured production Supply solutions to the wider market

16 The result We understand the challenges our AM systems customers face. A typical dental customer s issues: Potentially thousands of erroneous STL files/day to fix Tracking items right through production to their end point Controlling automated processes Controlling manual processes Integrating with inspection systems Post processing of AM parts and the tools required

17 Medical implants building on experience Adding medical implants to our production portfolio Developing solutions for production of craniomaxillofacial devices

18 Offer credible solution Understand the specific healthcare markets and their drivers, financial, legal and regulatory Uncover the issues facing our customers in their production environment Develop new and existing processes to complement AM Optimise additive manufacturing systems to get the best out of them

19 ADEPT - overview Advance-manufacture for Design-led Efficient Patient Treatment 3 year project led by Renishaw Focus on advancing the use of design and 3D printing technologies within craniomaxillofacial surgery. Part funded by the UK s innovation agency, Innovate UK and the Engineering and Physical Sciences Research Council (EPSRC).

20 ADEPT - aims Develop an end to end digital workflow for cranio-maxillofacial implant design and manufacture Improve surgical outcome Reduce end to end treatment timescale Deliver NHS cost savings

21 ADEPT - partners Renishaw coordinating R&D and technology supplier LPW Technology Ltd powder supplier ABMU Health Board clinical partner PDR, Cardiff Metropolitan University academic partner

22 ADEPT - demonstration

23 Offer credible solution Understand the specific healthcare markets and their drivers, financial, legal and regulatory Uncover the issues facing our customers in their production environment Develop new and existing processes to complement AM Optimise additive manufacturing systems to get the best out of them

24 Optimising AM systems why? Many parameters to change with no reference books for AM Layer thickness Powder type & safe handling Gas flow Scale factors Build strategy Exposure time Laser spot size Laser power Support structure thickness Stress relieving parts

25 What difference can optimisation make?

26 Why is optimisation needed? Default Optimised

27 1. Machine calibration Beam profile Power map Focus Scan field

28 1. Machine calibration II Beam profile analysis Scan field calibration

29 Relative Density 2. Density optimisation Specific Energy

30 Surface Roughness 2. Surface finish optimisation Vertical Horizontal Specific Energy

31 3. Accuracy Renishaw DS10 scanner > 4,000 points per feature

32 3. Accuracy II

33 4. Process validation I

34 4. Process validation II

35 Customer benefits - optimise blind? Starting from a commissioned AM system 140+ adjustable parameters in Autofab many are dependent on the values of others No textbooks to turn to Very little industry experience Renishaw can deliver big benefits in the early years of metal AM

36 Customer benefits - requirements

37 Customer benefits - chemical composition 0.25 Oxygen Nitrogen 0.2 Grade 5 Oxygen limit 0.15 Grade 23 Oxygen limit Grade 5/23 Nitrogen limit 0 Raw powder stock As-sintered Optimised heat treatment Subcontract

38 Volume Density (%) Customer benefits - powder Standard certificate Chemical composition Size range Particle Size Class (µm) Renishaw certificate Chemical composition Sieve analysis Rheometry bulk Laser size diffraction property Hall flow Shear cell Apparent density Morphology Angle of repose SEM Cross-section Tap density Moisture analysis True density by helium gas pycnometry Rheometry dynamic

39 Customer benefits - biocompatibility Infrared analysis Gas Chromatography Inductively Coupled Plasma Mass Spectroscopy (ICP-MS) Ion Chromatography Cytotoxicity Ultra Performance Liquid Chromatography (UPLC)

40 Offer credible solution Understand the specific healthcare markets and their drivers, financial, legal and regulatory Uncover the issues facing our customers in their production environment Develop new and existing processes to complement AM Optimise additive manufacturing systems to get the best out of them

41 Our AM journey so far Production of LaserPFM TM CoCr frameworks Additive product lines added LaserBridge implant bridges launched Involvement in first maxfac case

42 Our AM journey so far 2015 Launch of LaserImplants, August Launch of Laser RPDs, December Opening of Healthcare centre of excellence, December

43 Renishaw logo Thank you for listening Any questions?