Verdana Bold 28 - Materialise Software

Additive Manufacturing with EBM®
2014-04-16
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Overview
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2014-04-16
Overview
Applications
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Medical Implants
Aerospace
Arcam Products
Materials
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Core Benefits with EBM®
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Freedom in Design
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Excellent Material Properties
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Design for function
Integrated trabecular structures
for improved osseointegration
Enables mass customization
Controlled microstructure
Better than cast
Compliant with applicable
industry standards
Cost-Efficient Production
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High productivity
Material recycling
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EBM® - Electron Beam Melting
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The electron beam gun generates a
high energy beam (up to 3.000 W)
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The beam melts each layer of powder
metal to the desired geometry
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Extremely fast beam translation with
no moving parts
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High beam power -> high melt rate
(up to 80 cm3/h) and productivity
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Vacuum process -> eliminates impurities
and yields excellent material properties
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High process temperature (650 ºC
for titanium) -> low residual stress
and no need for heat treatment
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The EBM® Machine
EB Gun
Build Chamber
Heat Shield
Powder
Container
Powder Rake
Build Platform
Control Unit
Build Tank
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Medical Implants
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2014-04-16
Overview
Applications
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Medical Implants
Aerospace
Arcam Products
Materials
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Trabecular Structures™
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Design your unique trademark trabecular structure
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With CAD or with a Structure generator software
Optimize for osseointegration
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Pore geometry (no limitation)
Pore size (down to ~400 μm)
Porosity (up to ~85%)
Competitive manufacturing costs
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EBM® production cost, typical: < 2 €/cm3 trabecular structure
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Biocompatibility
Pictures of bone growing into EBM®-manufactured
titanium implants with Trabecular Structures™
Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials,
University of Gothenburg.
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Implant Categories
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Acetabular cups
Revision cups
Augments
Femoral stems
CMF
Spine
Tibial trays
Shoulders
Triflanges
Wedges
Femoral knees
In production
with EBM®
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Production Benefits
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Single-step production of solid and porous sections,
with structural continuity between them
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All-porous implants possible (augments, wedges, …)
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High process temperature gives low residual stress,
and no need for heat treatment after the build
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No secondary high temperature process to apply the
porous structure that could cause grain growth
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Arcam LayerQam™
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Camera-based quality verification system
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Additive Manufacturing provides a new melted surface for each layer
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The melting depth is thicker than the powder layer
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Camera-based monitoring of each melted layer provides porosity
control of the entire produced part
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Monitoring each layer hence provides a unique capability to verify
the full density of EBM-produced implants
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Post-Build Processing
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Remove and recycle excess powder
Machine inside with conventional CNC
Clean parts with ultrasonic and solvents
Quality Control with EBM® LogStudio™
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CE-certified & FDA-cleared
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CE-certified acetabular cups with integrated
Trabecular Structures™ since 2007
Implants with FDA clearance since 2010
> 40,000 cups implanted
2% of the global production of acetabular cups
is now manufactured with EBM®
Adler Ortho, IT
2007 -
Lima, IT
2007 -
Exactech, US
2010 -
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Fixa Ti-Por™ Acetabular Cup
CE-certified since 2007
Material:
Build time:
Ti6Al4V
16 cups in
8 hours
Courtesy of Adler Ortho s.r.l.
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DELTA TT™ Acetabular Cup
CE-certified since 2007
Material:
Build time:
Ti6Al4V
16 cups in
8 hours
Courtesy of Limacorporate S.p.a.
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Novation Crown Cup InteGrip®
FDA-approved since 2010
Material:
Build time:
Ti6Al4V
16 cups in
8 hours
Courtesy of Exactech, Inc.
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Agilis Ti-Por™ Acetabular Cup
CE-certified since 2011
Material:
Build time:
Ti6Al4V
16 cups in
8 hours
Courtesy of Adler Ortho s.r.l.
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DELTA TT™ Revision Cup
CE-certified since 2007
Material:
Build time:
Ti Grade 2
4 cups in
13 hours
Courtesy of Limacorporate S.p.a.
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DELTA TT™ Augment
CE-certified since 2007
Material:
Ti6Al4V
Courtesy of Limacorporate S.p.a.
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Parva™ Femoral Stem
CE-certified since 2011
Material:
Ti6Al4V
Courtesy of Adler Ortho s.r.l.
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FUSE™ Lumbar PLIF Cage
CE-certified since 2009
Material:
Ti Grade 2
Courtesy of Medtronic Inc.
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Tesera™ ALIF Cage
FDA-approved since 2013
Material:
Ti6Al4V
Courtesy of Renovis Surgical Technologies, Inc.
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Customized CMF Implant
Material:
Courtesy of Dr. Stephen Rouse.
Ti6Al4V
More than 70
EBM®-produced
customized
trabecular CMF
implants have been
implanted at the
Walter Reed
National Military
Medical Center in
Bethesda, MD, USA.
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Summary
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Use CAD or a structure generator software to design
your unique trademark trabecular structure
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Use EBM® to produce your Trabecular Structures™
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EBM® is a unique single-step production method for
solid and porous implants
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EBM® provides structural continuity between solid and
porous sections, and requires no heat treatment
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EBM® is a proven and cost-efficient technology,
with thousands of implanted CE-certified products
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Arcam Products
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Overview
Applications
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Medical Implants
Aerospace
Arcam Products
Materials
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Arcam Q10
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For implant production,
in titanium alloys
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Build envelope
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200 x 200 x 180 mm
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Higher productivity
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Improved resolution
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Arcam LayerQam™
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Arcam MultiBeam™
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Integration with Streamics™
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Powder Recovery System
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> 95% recovery of
unmelted powder
Minimal dust generation
for safe operation
Closed circuit until powder
recovery is completed
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Training & Maintenance
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Support & Maintenance
agreements to maximize
use of machines, incl.
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Application support
Periodic maintenance
Spare parts
Emergency visits
Support hot-line
Training packages to
ensure operator skills
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Basic training
Advanced training
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Arcam Powder Metals
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Pre-alloyed powder
Powder fractions selected for safe operation and handling
Verified material properties
Chemical composition in accordance with applicable standards
Optimized process parameters
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Materials
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2014-04-16
Overview
Applications
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Medical Implants
Aerospace
Arcam Products
Materials
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Materials Portfolio
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The materials currently supplied by Arcam are
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For these materials Arcam has
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Titanium Ti6Al4V (Grade 5)
Titanium Ti6Al4V ELI (Grade 23)
Titanium cpTi (Grade 2)
Cobalt-Chrome, ASTM F75
Established a validated powder supply chain
Optimized process parameters for the supplied powder
Verified material properties of the built material
Excellent properties for
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Strength
Elasticity
Fatigue
Chemical composition
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EBM® - Core Benefits
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Freedom in Design
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Excellent Material Properties
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Cost-Efficient Production
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Contact
Thank you for your attention!
Arcam AB
Krokslätts Fabriker 27A
SE-431 37 Mölndal, Sweden
Phone: +46 31 710 32 00
Web site: www.arcam.com
E-mail: [email protected]
Arcam - CAD to Metal®
2014-04-16
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