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Tecnalia. Inspiring Business

Tecnalia. Inspiring Business

Highly customized and affordable implants by a new hybrid 3D printing technology

2016.11.11

A new 3D printing technology available for the manufacture of implants customized to the patient at affordable cost

TECNALIA RESEARCH & INNOVATION together with seven European companies and research institutes takes part in the EU-funded research and innovation project “FAST”, which stands for “Functionally graded Additive Manufacturing (AM) scaffolds by hybrid manufacturing”, to make a new 3D printing technology available for the manufacture of implants customized to the patient at affordable cost. Specific patient implants can promote effective preoperative planning, shortening the time of surgery and improving the lifetime of the implant.

The medical sector is now the fourth industrial sector using Additive Manufacturing. Compared to traditional methods, this technology has the capabilities to produce time and cost-efficiently customised surgical and prosthetic devices, surgical implants and scaffolds for tissue regeneration individually for each single patient. 

Scaffolds production for tissue regeneration is one of the main fields where the  “Design for Function” feature of AM makes the difference relative to the other production techniques, in particular  if in the production process all the needed “functions” can be introduced: shape and

porosity, mechanical stability and biochemical properties such as cell growth control or antibiotic function. The FAST project aims to develop a cost-efficient technology to integrate all these “functions” in a single AM process that is even capable to produce gradients in the bulk or surface properties of the individual scaffold. 

Thus not only customized shapes of scaffolds can be produced, but also bulk and surface properties of the scaffold material can be tailored according to the specific needs of each individual patient.

In practice this will translate into improved tissue ingrowth and regeneration properties combined with higher structural stability of implants. Furthermore, the incorporation of smart fillers with bio-active properties into the scaffold material will reduce the risk of post-surgery infections. Thus, the FAST technology has the potential to increase the patients’ comfort at an affordable cost for them and the healthcare system. The project will demonstrate its developments in a small pilot production of scaffolds for bone regeneration to be tested in a pilot in vivo trial.

The FAST project is scheduled to run for four years from 1st December 2015 to  30th  November 2019 with a budget of 4,9 MEUR, which is funded by the European Union under the H2020 Framework Programme for Research and Innovation.Advanced Orthopedic Technologies, Implants and Regenerative Products. The global market for advanced orthopedic technology is anticipated to increase from $36.4 billion by 2014 to $42.2 billion by 2019, with a compound annual growth rate of 3% from 2014 to 20193. The global bone grafts and substitutes market was valued at USD 2.35 billion in 2014 and is anticipated to expand at a CAGR of 4.5% from 2015 to 2023 to reach USD 3.48 billion in 20234. As skeletal tissue regeneration products based on 3D porous biomaterials – 3D scaffolds - can be placed in the same commercial segment the FAST technology can be seen as a tremendous opportunity to impact current commercialization and place Europe at the forefront of the regenerative medicine field. 

BioScaffolder

Fig. 1: BioScaffolder 3.1 of the FAST project partner GeSIM GmbH to produce scaffolds for tissue regeneration1

Bone Scaffolds

Fig. 2: printing of bone scaffolds2

FAST project partners:

  • Abalonyx AS,  Norway
  • Fraunhofer Institute for Surface Engineering and Thin Films  IST, Germany
  • Fundacion Tecnalia Research & Innovation, Spain
  • GeSIM Gesellschaft für Silizium-Mikrosysteme mbH, Germany
  • Maastricht University, The Netherlands
  • Nadir S. r. l., Italy
  • Polyvation  BV, The Netherlands
  • Prolabin & Tefarm S. r. l., Italy

Press contact via the project coordinators:

Dr. Lorenzo Moroni, Maastricht University, l.moroni@maastrichtuniversity.nl and Dr. Alessandro Patelli, Nadir S.r.l., patelli@nadir-tech.it

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