The emergence of additive manufacturing technologies into the medical and orthopedic fields has been transformative, advancing device intricacy and performance while offering patient-specific solutions. Additive manufacturing continues to be one of the fastest growing technologies in the orthopedic field. While 3D print resolution has steadily advanced during this evolution, post-processing is often a necessity to remove surface imperfections, including visible layer lines, loosely adherent residual beads, irregularities on the build surface, and other surface defects. These post-processes offer critical improvements to the aesthetic appearance and overall device functionality.
Grit-blasting with MCD Apatitic Abrasive has been demonstrated as a highly effective option for removing material traces and abnormalities resultant from the additive manufacturing process. Elimination of these surface imperfections will result in a more uniform finish of superior quality and consistency. As an added value, the inherent formation of micropits on the device surface (if desired) can provide an even more complex textured structure for improved osseointegration.
This conference will review a series of post-processing case studies including comprehensive qualitative and quantitative surface evaluations. All represent engineered collaborative accomplishments with successful FDA 510(k) approved or approval pending additive device systems.
- Case Study #1 To remove loosely adherent residual beads on the porous additive surface.
- Case Study #2 To remove surface abnormalities and defects on the additive build surface, while roughening the entire device to create a more uniform textured surface.
- Case Study #3 To quantify the change to surface profile with increased MATRIX MCD® grit-blast application time.
Learning Objectives:
- Recognize the importance of post-processing to remove surface imperfections, including visible layer lines, loosely adherent residual beads, irregularities on the build surface, and other surface
- Understand the value proposition for grit-blasting with biocompatible MCD Apatitic Abrasive, a granular, multi-phase calcium phosphate intended to increase the surface uniformity of additively manufactured devices without embedded residual media.
- Learn how to implement such novel post-processing as part of one's own manufacturing process, including "tips of the trade" and suggestions for future considerations as additive manufacturing continues to evolve.
