Week 3: Polymer AM & Medical Applications
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Questions and Answers

What is a major reason for the growth in the medical applications of additive manufacturing?

  • Elimination of custom devices
  • Higher patient expectations (correct)
  • Lower survival rates for diseases
  • Decreasing technology costs

Additive manufacturing is primarily focused on mass-produced devices in the medical field.

False (B)

Name three examples of customised devices in additive manufacturing for medical applications.

Maxillofacial prostheses, dental aligners, artificial limbs.

Additive manufacturing can influence both customised devices and _______ devices.

<p>mass-produced</p> Signup and view all the answers

Match the following customised medical devices with their descriptions:

<p>Drill guides = Assist with precise surgical procedures Burns splints = Provide support and protection for burn victims Custom orthoses = Aid in movement and offer support for body parts Dentures = Replace missing teeth</p> Signup and view all the answers

What is one benefit for patients regarding localized scanning and manufacturing?

<p>Minimizing travel to visit specialists (B)</p> Signup and view all the answers

The NHS incurs costs of over £700 million per year due to missed appointments.

<p>True (A)</p> Signup and view all the answers

What are some potential benefits for medical staff when it comes to localized scanning?

<p>They can focus on specialist parts of the job.</p> Signup and view all the answers

Reduced manual labour leads to quicker treatment and less ________ during normal use of the product.

<p>pain</p> Signup and view all the answers

Match the following benefits to the correct groups (Patient, Medical Staff, NHS):

<p>Less painful treatment = Patient Higher patient throughput = Medical Staff Lower transport costs = NHS Shortened waiting lists = NHS Quicker treatment = Patient</p> Signup and view all the answers

What is a benefit of using non-contact methods for producing custom devices?

<p>Reduced patient anxiety during the procedure (D)</p> Signup and view all the answers

Traditional methods for producing customised devices are often less accurate than modern techniques.

<p>True (A)</p> Signup and view all the answers

What is the primary purpose of a burn mask?

<p>To aid healing and prevent scar tissue formation.</p> Signup and view all the answers

The traditional method of construction for prosthetic legs involves producing a physical _____ of the remaining limb.

<p>mould</p> Signup and view all the answers

Match the following benefits with their corresponding types of production methods:

<p>Non-contact scanning = Reduced patient discomfort Traditional methods = Accurate mould production 3D printing = Faster adaptability Labour-intensive processes = High need for skilled labor</p> Signup and view all the answers

Which of the following is NOT mentioned as a drawback of traditional methods?

<p>Easy to implement (A)</p> Signup and view all the answers

Weight saving is considered a factor in improving the function of devices.

<p>True (A)</p> Signup and view all the answers

Name one reason why traditional methods may require adjustments after fitting.

<p>Incorrect fit.</p> Signup and view all the answers

What is a potential disadvantage of traditional mould-making for prosthetics?

<p>It may require a new prosthetic over time. (A)</p> Signup and view all the answers

Using 3D printing for prosthetic sockets eliminates all manual steps in the process.

<p>False (B)</p> Signup and view all the answers

List one advantage of using 3D printing to create prosthetic sockets.

<p>Improved accuracy and quality.</p> Signup and view all the answers

The stakeholder that is primarily concerned with the management of healthcare resources is the ______.

<p>NHS</p> Signup and view all the answers

Match the following stakeholders with their primary concern:

<p>Patients = Quality of life and mobility Carers/family = Support for their loved ones Medical Staff = Effective patient care NHS = Cost-effectiveness of treatments</p> Signup and view all the answers

What is one way to streamline the prosthetic fitting process?

<p>Minimize the number of consultations. (C)</p> Signup and view all the answers

3D printing of prosthetic sockets can potentially be more expensive than traditional methods.

<p>True (A)</p> Signup and view all the answers

Why is it important to consider the effects on stakeholders in the prosthetic fitting process?

<p>To ensure decisions benefit all parties involved.</p> Signup and view all the answers

Who is involved in the impression taking stage of the process?

<p>Prosthetist, Patient (C)</p> Signup and view all the answers

The production of the final prosthetic includes activities like fitting and colour-matching.

<p>True (A)</p> Signup and view all the answers

What are the costs associated with the patient consultation stage?

<p>Patient travel &amp; accommodation, clinic time &amp; staff salaries</p> Signup and view all the answers

In the impression taking stage, costs include patient travel, accommodation, staff salary, laboratory time, and _____ for materials.

<p>costs</p> Signup and view all the answers

Match each stage of the process with its associated costs:

<p>Patient consultation = Patient travel &amp; accommodation, clinic time &amp; staff salaries Impression taking = Patient travel, accommodation, staff salary, laboratory time, materials Production of mould = Laboratory time, staff salary, materials Production of final prosthetic = Laboratory time, staff salary, materials, patient travel &amp; accommodation</p> Signup and view all the answers

What potential advantage does eliminating the patient visit in the impression taking stage offer?

<p>Faster &amp; more comfortable experience for the patient (A)</p> Signup and view all the answers

The tooling route refers to a completely digital process without any patient involvement.

<p>False (B)</p> Signup and view all the answers

Identify one area where steps of the process can be eliminated or replaced.

<p>Eliminate patient visit in impression taking with a 3D scan.</p> Signup and view all the answers

What is a main benefit of optimizing the schedule of work in the manufacturing process?

<p>Reduced overall process costs (C)</p> Signup and view all the answers

The production of molds from patterns remains unchanged regardless of the manufacturing process.

<p>True (A)</p> Signup and view all the answers

What is one method mentioned for producing patterns in manufacturing?

<p>3D CAD &amp; AM</p> Signup and view all the answers

The _______ process of manufacturing often accounts for only a small fraction of the total costs.

<p>device</p> Signup and view all the answers

Match the following Additive Manufacturing processes with their descriptions:

<p>Fused Deposition Modelling = Molten plastic is extruded to create a 3D object. Material Extrusion = A process that shapes materials by forcing them through a nozzle.</p> Signup and view all the answers

Which of the following is a potential concern during the Fused Deposition Modelling process?

<p>Emission of hazardous fumes and particulates (D)</p> Signup and view all the answers

The primary focus of the session is on metal AM processes.

<p>False (B)</p> Signup and view all the answers

What do the overall process costs of manufacturing devices include beyond the physical costs?

<p>Whole treatment process, beneficiary considerations, potential bottlenecks.</p> Signup and view all the answers

What is a primary focus of additive manufacturing (AM) in medical applications?

<p>Customised devices (D)</p> Signup and view all the answers

Customised devices in medical applications can include dental aligners and artificial limbs.

<p>True (A)</p> Signup and view all the answers

What is one common benefit of using additive manufacturing in medical applications?

<p>Customization and improved fit for patients</p> Signup and view all the answers

The production of medical devices using additive manufacturing can lead to improved ________ for patients by creating tailored solutions.

<p>outcomes</p> Signup and view all the answers

Match the following medical devices with their uses:

<p>Maxillofacial prostheses = Facial reconstruction Burns splints = Wound protection and support Custom orthoses = Support for limbs Dental aligners = Tooth alignment</p> Signup and view all the answers

What is one benefit to medical staff from localized scanning and manufacturing?

<p>Ability to see higher numbers of patients (D)</p> Signup and view all the answers

NHS incurs expenses of over £700 million annually due to missed appointments.

<p>True (A)</p> Signup and view all the answers

What is a potential benefit for patients resulting from reduced manual labor in the treatment process?

<p>Quicker treatment</p> Signup and view all the answers

Reduced manual labor leads to less ______ during normal use of the product.

<p>pain</p> Signup and view all the answers

Match the following groups with their respective benefits:

<p>Patients = Quicker treatment Medical Staff = Focus on specialist parts of the job NHS = Lower transport costs</p> Signup and view all the answers

What is a significant cost associated with the production of the final prosthetic?

<p>Laboratory time (B)</p> Signup and view all the answers

The impression taking stage can be eliminated if the patient already has a 3D scan.

<p>True (A)</p> Signup and view all the answers

List one potential advantage of using additive manufacturing for producing prosthetics over traditional methods.

<p>Customization of devices</p> Signup and view all the answers

In the milling stage, key costs include staff salaries, laboratory time, and _____ for materials.

<p>expenses</p> Signup and view all the answers

Match the stage of the prosthetic process with its associated people involved:

<p>Patient consultation = Surgeon, nurse, prosthetist, receptionist Impression taking = Prosthetist, patient Production of mould = Prosthetist Production of final prosthetic = Prosthetist, patient</p> Signup and view all the answers

Which stage involves costs related to patient travel and accommodation?

<p>Impression taking (A), Patient consultation (C)</p> Signup and view all the answers

Adding value to the patient consultation can be achieved by scanning patients in batches.

<p>True (A)</p> Signup and view all the answers

Identify one key stakeholder involved in the impression taking stage.

<p>Prosthetist</p> Signup and view all the answers

What is a primary drawback of traditional methods for producing customized devices?

<p>Labor-intensive (D)</p> Signup and view all the answers

Non-contact methods for producing custom devices can help reduce patient anxiety during the fitting process.

<p>True (A)</p> Signup and view all the answers

What is the purpose of a burn mask?

<p>To aid healing and prevent scar tissue formation on severe facial burns.</p> Signup and view all the answers

The traditional method to create a prosthetic socket involves making a physical _____ of the remaining limb.

<p>mould</p> Signup and view all the answers

Match the following terms with their descriptions:

<p>Geometric complexity = Fit to individual shapes and sizes Fluid flow = Managing the movement of fluids through devices Weight saving = Reducing the overall weight of devices Cellular growth = Enhancement of biological tissue generation</p> Signup and view all the answers

What is one of the psychological benefits of using non-contact methods?

<p>Increases patient comfort (B)</p> Signup and view all the answers

Additive manufacturing processes are considered slower than traditional methods for customized device production.

<p>False (B)</p> Signup and view all the answers

What type of manufacturing is often skilled-dependent and slow?

<p>Traditional methods</p> Signup and view all the answers

What is a potential benefit of localized scanning and manufacturing for prosthetics?

<p>Reduced manual labor (D)</p> Signup and view all the answers

Using 3D printing for prosthetic sockets completely removes the need for manual steps in the process.

<p>False (B)</p> Signup and view all the answers

Name one stakeholder that must be considered when making decisions in the prosthetic fitting process.

<p>Patients</p> Signup and view all the answers

Minimizing the number of ________ in the prosthetic fitting process can benefit both patients and medical staff.

<p>consultations</p> Signup and view all the answers

Which of the following may require adjustments to a prosthetic over time?

<p>Changes in limb shape (C)</p> Signup and view all the answers

3D printed prosthetic sockets tend to be less expensive than traditional sockets.

<p>False (B)</p> Signup and view all the answers

List one disadvantage of traditional mould-making for prosthetics.

<p>It can be painful for the patient.</p> Signup and view all the answers

What is a benefit of using additive manufacturing in the medical field?

<p>Customization of devices (C)</p> Signup and view all the answers

Additive manufacturing processes are primarily hazardous and cannot be used in an office environment.

<p>False (B)</p> Signup and view all the answers

What is one potential bottleneck that can be reduced in the medical device manufacturing process?

<p>Patient visits</p> Signup and view all the answers

The _______ process in manufacturing includes activities like fitting and colour-matching for prosthetics.

<p>production of final prosthetic</p> Signup and view all the answers

Match the following additive manufacturing processes with their primary feature:

<p>Material Extrusion = Fused Deposition Modelling using molten plastic Powder Bed Fusion = Laser sintering of powdered materials Vat Polymerization = Using light to cure liquid resin Material Jetting = Droplets of materials are deposited layer upon layer</p> Signup and view all the answers

What does the term 'optimizing the schedule of work' in manufacturing refer to?

<p>Reducing overhead costs and improving efficiency (D)</p> Signup and view all the answers

The overall cost of manufacturing a device is often only a small fraction of the total process cost.

<p>True (A)</p> Signup and view all the answers

What are the two main processes involved in the production of a mould from a pattern?

<p>Design and manufacture</p> Signup and view all the answers

Flashcards

Why is there such a demand for medical applications?

The increasing age of the population, rising survival rates for major illnesses, and cost restrictions all contribute to the growing demand for medical applications.

What are the innovations AM brings to the medical field?

Additive Manufacturing (AM) can innovate by creating new products and process chains, impacting the production of both customized and mass-produced medical devices.

What are examples of customized medical devices?

Customized medical devices like maxillofacial prostheses, dentures, orthotics, and artificial limbs cater to individual needs and ensure proper fit.

How are customized devices used in surgeries?

Drill guides and surgical planning models are customized devices used to assist in surgical procedures, providing precise guidance and visualization.

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Why use AM for implants despite higher cost?

While AM devices may cost more than traditional ones, their benefits like customization, complex geometries, and unique materials justify their use in specialized scenarios.

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Geometric complexity

The process of analyzing and improving a design based on its overall performance and cost effectiveness.

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Fit to individual

Creating a product that perfectly fits an individual's unique shape and size.

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Weight saving

Reducing the weight of a product without compromising its functionality.

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Fluid flow

The way liquids or gases move through a product.

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Cellular growth

The way cells grow and divide.

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Traditional methods for custom medical devices

Traditional methods for producing custom medical devices often involve manual craftsmanship, leading to several disadvantages.

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Burn mask

A mask designed for burn victims to aid healing and prevent scar tissue formation.

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Traditional burn mask construction

A common traditional method for creating burn masks involves taking a plaster cast of the patient's face, which can be painful and anxiety-inducing.

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Digital technologies in Medical Devices

Utilizing digital technologies, such as 3D scanning and printing, to create personalized medical devices like prosthetics, which cater to individual needs and provide a precise fit.

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Digital patient modeling

The process of using digital technologies to create a virtual representation of a patient's anatomy, often used for planning surgical procedures or designing customized medical devices.

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Customized medical device

A type of medical device that is tailored to an individual's needs, often using digital technologies for precise design and fabrication.

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Benefits of digital technologies in healthcare

The benefits of using digital technologies in medical device production include shorter waiting times, reduced travel for patients, and lower costs for the healthcare system.

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Digital technologies in maxillofacial prostheses

The use of digital technologies for creating maxillofacial prostheses offers benefits such as a more exact match for the patient's needs, reducing the need for adjustments and improving overall comfort.

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Traditional prosthetic mold-making

The process of creating a mold of a patient's limb to create a prosthetic socket. It involves manual steps like taking measurements, aligning the mold, and fitting the socket. It is often painful for the patient, especially directly after an injury. The process can also be wasteful due to the use of sacrificial molds.

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3D printed prosthetic socket

The use of 3D scanning and printing to create a prosthetic socket. It allows for a more customized fit and can be completed more quickly than traditional methods. However, it may be more expensive than traditional methods.

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Stakeholders in prosthetic development

The people or organizations who are affected by a product or service. In the context of prosthetics, stakeholders can include patients, healthcare staff, insurance providers, and government agencies.

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Process chain analysis

The process of analyzing and optimizing the steps involved in producing a product or service. It considers the potential benefits and drawbacks of each step for all relevant stakeholders.

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Streamlining consultations

Minimizing the number of consultations with patients to improve the efficiency of the prosthetic process. This can be achieved by using technology like 3D scanning, allowing the same information to be gathered faster.

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Localized prosthetic manufacturing

The use of 3D printing technology to create prosthetic sockets that can be manufactured locally. This can reduce the need for physical transport of the patient and improve overall accessibility.

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Benefits of 3D printed sockets

The benefits of using 3D printing technology to produce prosthetic sockets, including faster production times, higher quality products, and less manual labor required.

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Optimizing the prosthetic process chain

The goal of prosthetic development is to create a product that benefits all stakeholders, including the patient, healthcare staff, and insurance providers. 3D printing has the potential to achieve this by creating a more efficient and cost-effective process while ensuring a high-quality outcome.

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Patient Consultation

The stage where a patient meets with medical professionals to discuss their needs and treatment options. This involves gathering information, understanding the patient's situation, and planning the treatment process.

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Impression Taking

The process of taking precise measurements of a patient's body part, usually using plaster or a digital scanner, to create a mold for the prosthetic device. This ensures accurate fit and functionality.

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Scanning at Consultation

The stage where a 3D scan of the patient is taken during the initial consultation, eliminating the need for a separate impression taking appointment. This streamlines the process and reduces patient inconvenience.

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AM Advantages

The benefits of using Additive Manufacturing (AM) in the production process, including faster turnaround times, customized designs, reduced waste, and the ability to create complex structures .

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AM Limitations

The limitations of using Additive Manufacturing (AM) in the production process, such as potential cost issues, material limitations, scalability concerns, and the need for specialized expertise. These limitations need to be considered when deciding whether AM is the right technology for a specific application.

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Tooling Route Prosthetics

A prosthetic device crafted using traditional manufacturing techniques, often involving a series of molds and castings.

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AM Prosthetics

A prosthetic device crafted using Additive Manufacturing (AM), often involving a digital 3D model and a printing process.

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Customization

The process of tailoring a prosthetic device to the specific needs and measurements of an individual patient.

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Additive Manufacturing (AM)

A manufacturing process where layers of material are built up, often controlled by a computer, to create a three-dimensional object. This is also known as 3D printing.

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Fused Deposition Modeling (FDM)

A type of AM process where a melted plastic filament is extruded layer by layer to create a 3D object.

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Medical Applications of AM

AM techniques are increasingly used to manufacture medical devices, offering advantages like creating custom solutions, reducing the need for multiple surgeries, and improving patient outcomes.

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Custom Prosthetics

The process of designing and creating prosthetic devices that are custom-fitted to a patient's unique anatomy, improving both function and appearance.

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AM for Burn Masks

Using AM to create burn masks tailored to a patient's specific needs. This offers advantages over traditional methods, like plaster casts, by providing a more comfortable and precise fit.

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Digital Technologies in Healthcare

An array of digital tools and methods, including 3D scanning, CAD, and AM, used in the medical field to create personalized devices and optimize treatment plans.

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AM for Maxillofacial Prosthetics

The use of AM to create maxillofacial prostheses (devices for the face and jaw) that match a patient's specific needs. This leads to a more precise fit, reduces the need for adjustments, and improves overall comfort.

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AM for Surgical Guides

The use of AM to create surgical fixtures that guide the surgeon during procedures, increasing accuracy and improving patient outcomes.

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Study Notes

Additive Manufacturing - Medical Applications

  • Additive manufacturing (AM) is a growing sector
  • Factors contributing to the growth of AM in medicine include:
    • Ageing population
    • Increased survival rates for major diseases
    • Cost constraints, particularly for the NHS
    • Patient expectations
    • High value (both financial and otherwise)
  • AM is impacting medical devices in two areas
    • Customised devices
    • Mass-produced devices
  • Focus on week is on customised medical devices

Examples of Customised Devices

  • Maxillofacial prostheses
  • Dentures
  • Dental aligners
  • Custom orthoses
  • Artificial limbs
  • Burns splints

Customised Devices to Assist with Surgeries

  • Drill guides
  • Surgical planning models

Customised Implants

  • AM devices can cost more than traditional devices, but
  • Benefits of AM can be geometric complexity, fit to individual, weight saving, and fluid flow
  • Considerations of the overall process chain need to be considered

Traditional Methods

  • Often hand-made
  • Labour-intensive
  • Skill-dependent
  • Slow
  • Can be inaccurate
  • May involve one or more visits to a specialist
  • Can involve adjustments/replacement if fit is incorrect
  • May involve physical contact

Examples of Traditional Methods - Burn Masks

  • Traditional burn mask construction using plaster to create a mould and then a plastic mask
  • Can be painful
  • Patients may become anxious

Traditional Method of Construction - Benefits & Considerations

  • Benefits include effectiveness
  • Disadvantages include the physical contact, pain, and patient anxiety during the process
  • Potential alternatives involve non-contact scanning & AM to create a user-friendly mould process, but this potentially incurs higher financial costs

Traditional Method of Production - Prosthetic Legs

  • Steps involve producing a physical mould of the remaining limb, followed by manual finishing, creation of a socket, and alignment
  • Procedure can be performed in a load-bearing situation and can be painful soon after injury
  • Consider using AM to 3D print the socket
  • Consider potential advantages & disadvantages and the stakeholder impact

Stakeholders

  • Patients
  • Carers/family
  • Medical staff
  • NHS (consider how considerations might differ in various countries)
  • Other stakeholders (employers, colleagues, government)

Benefits of using AM in different stakeholders

  • Patient: Less travel, reduced time away from work, less stress, more patients serviced
  • Medical Staff: Higher patient throughput, focus on specialist input
  • NHS: Reduction in missed appointments, lower transport costs, shorter waiting lists

AM Opportunities

  • Minimise number of consultations
  • Localise Scanning & Manufacture
  • Reduce manual labour

AM - Maxillofacial Prostheses

  • This particular form of prostheses is designed to match location, geometry, and colour
  • Using digital technologies for value addition at each stage
  • Tooling routes

Stages of AM Process

  • People involved & Costs: A breakdown of the people who are typically involved in each stage and the associated costs for a prostheses production
    • Patient Consultation
    • Impression Taking
    • Design and Manufacture of Pattern
    • Production of Mould from Pattern
    • Production of Final Prosthetic (Colour Matching & Fitting)
  • Opportunities : Scan patient at consultation, eliminate patient visit, remove stages (eg. 3D CAD & AM to produce), the same for production of mould, same for production of final prosthetic

Summary of AM

  • AM is often not the full cost of treatment, though it is a small fraction of the overall cost
  • There are potential bottlenecks
  • Identify the stakeholders and the potential benefits to everyone involved in treatment
  • Consider the pros and cons of different AM applications to identify appropriate procedures

Other 'Non-Metals'

  • Different materials are considered for AM.
  • Despite current limitations, new developments are coming through
  • All processes require understanding of material properties to be viable

Sheet Lamination

  • Arguably the simplest AM process
  • Profiles of cross-sections are cut from sheet materials, then stacked or bonded
  • No single system; various methods of bonding
  • Patenting is not possible due to the method’s simplicity
  • Any material available in plate or sheet form is possible

EOS Laser Sintering

  • Coate foundry sand
  • Used to produce one-off castings
  • Developed to help BMW make engine blocks
  • Multiple similar processes

Direct Shell Production Casting

  • Based on MIT 3D printing principle
  • Creates investment casting shells directly
  • Parts will need some post-production finishing

Figulo

  • Ceramic process based on MIT 3D Printing technology
  • Several design restrictions
  • Low detail; no moving parts/assemblies
  • Certain geometries difficult to produce
  • Parts glazed after production

Medical Materials (Applications)

  • Sterilizable devices (surgical equipment etc)
  • Bio-compatible materials
  • Bio-absorbable materials
  • Bio-active materials

Construction (Applications)

  • Production of emergency housing
  • More complex architecture
  • Ventilation incorporation
  • Pipe-work
  • Termite mounds

Solarsinter

  • Combine sun & sand to fuse silica (Desert)
  • Sustainable process for future

'Moondust'

  • Consider transportation of materials
  • Use of the Moon's materials in AM (e.g. Laser Sintering)

Food (Applications)

  • Market for personalised food
  • Food for long-term missions
  • Ability to create taste, consistency, and aesthetics

Ashes (Applications)

  • Laser sintering of ashes for keepsake

Additional Considerations

  • The shift in some instances away from one machine doing everything in AM processes
  • Identifying specific applications appropriate for specific AM processes
  • Consider the potential of the following slides in other non-metal applications

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Additive Manufacturing Principles and Applications - MEC454

Description

Explore the advancements of additive manufacturing in the medical field through this quiz. Test your knowledge on custom medical devices, their benefits, and implications for patients and medical staff. Understand how localized scanning and production can transform healthcare delivery.

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