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by Erin Stone

Direct Metal Laser Sintering offers Optimal Medical Implant Synergy

Spinal implants manufactured using 3D metal printing, or Direct Metal Laser Sintering (DMLS), have been the standard OEM sample to highlight complex latticed geometries. The question being, have any of those cool looking implants been used in the real world? Great new for all DMLS users and manufacturers – 4WEB Medical announced this week that 3,000 of their DMLS spinal implants have been successfully used by surgeons. Even better, the relatively rough surface finish associated with 3D printed metal parts creates an even better patient outcome. According to 4WEB, ” The truss implant designs have a distinctive open architecture, which allows for up to 75% of the implant to be filled with graft material to maximize bone incorporation.The 4WEB Medical ALIF device has a bi-convex surface that brings the implant and graft material closer to adjacent bone across the entire end plate rather than just around the outside edge. This in addition to a unique implant surface texture dramatically improves initial fixation and reduces the chance of migration.”

As a DMLS manufacturer, i3D MFG™ works closely with its clients on surface finish requirements, a commonly misunderstood piece of 3D metal printing. 3D metal parts are nearly 100% dense, allowing for any post process associated with machined or cast parts; however, clients often expect parts to come straight off the DMLS machine with near mirror polish. The reality is that the initial surface finish for a DMLS part before post process ranges form 125-300 Ra depending on the metal. 4WEB’s spinal implant leaves the rough surface which enhances the effectiveness of the implant. This is a huge shift in how we think about design, incorporating roughness as an innovative tool. Not all applications will achieve this type of synergy between the raw DMLS part and function, but as we shift towards design-for-3D, it’s worth taking note of the match between DMLS and medical implant advancements.


Image from: 4webmedical.com

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Direct Metal Laser Sintering offers Optimal Medical Implant Synergy