INGEO - Research & Design
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INGEO - Research & Design
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Rapid prototyping


For some years INGEO deals rapid prototyping applied to the medical field.
Rapid prototyping is an innovative technology that makes possible the production of objects with complex geometry directly from the mathematical
model of the object created on a three-dimensional CAD system.

INGEO - Rapid prototyping 3d model of mandibulaINGEO uses rapid prototyping to print in 1:1 scale three-dimensional models reproducing the anatomical structures of the skull, skeleton and whole human body. These models are then used in maxillo-facial surgery and orthopedic intervention on the spine. The three-dimensional reconstruction of skeletal structures may also serve for the analysis and treatment of:
Trauma
Congenital disorders
Neoplastic disorders
Reconstructive surgery
Plastic surgery
Oral surgery
Osteogenethic distraction

INGEO mainly uses the technique of 3D Printing, which use Calcium Sulfate powder (not biocompatible) agglomerated with glue sprayed with the technique of ink-jet printing.

Rapid prototyping - 3D Printing

Stages of rapid prototyping can be summarized as:
1. CAD 3D
2. Generation of .STL file
3. Orientation of the workpiece in 3D printer
4. Running the slicing
5. Creating support
6. Removing and cleaning support
7. Final prototype

INGEO recently adopted a 3D printing technique using a trasnparent resin that allows you to observe some internal anatomical structures, such as the mandibular canal (very useful information for implantology procedures).

Beside the use of transparent resins, for the biomedical applications, INGEO has the possibility to print titanium alloy objects with EBM technology. Below a AALEA (www.aaleaoffshore.com) part used for a manipulator with seven functions.

The phases of .STL file generation for 3D printing

INGEO - Rapid prototyping
Opening and analysis of DICOM images
INGEO - Rapid prototyping
   Image processing in 3D CAD

INGEO - Rapid prototyping
Creation of 3D model
INGEO - Rapid prototyping
   File .STL export for printing

The prototype created by 3D printing reproduces in detail the anatomy of the patient and allows the doctor to quickly obtain information on the best clinical case in question and to plan the intervention.

Maxillo-facial rapid prototypingThis also implies greater precision, greater speed
of execution (because plates and screws are shaped before the operation), less time in the operating room and, therefore, less risk to the patient.
The same patient can understand better his/her defect and disease and the surgery which he/she will undergo.

Here are the main benefits arising from the use of rapid prototyping in the medical field:

  • Pre-surgical planning
  • Customization of surgical devices
  • Time reduction of intervention in the operating room
  • Easily communication between doctors
  • Improving the doctor-patient communication
  • Protection in case of medico-legal disputes with patients
  • Preparation to real-life by doctors in specific courses


Materials used for printing the three-dimensional models

INGEO uses different materials for the prototyping of anatomical models. In addition to the above mentioned Calcium Sulfate powder (non-biocompatible material) and trasparent resin, INGEO has the ability to print with resin autoclavable, SI500 yellow opaque resin and pure titanium grade medical (Ti6Al4V, Grade 5). News concerning medical models have been proposed: the use of multimaterial able to highlight the root of the tooth and alveolar nerve.

Below are shown some of the prototypes made by INGEO.

INGEO - Rapid prototyping using synthetic calcium phosphate
Mandible prototype in Si powder (not biocompatible)
INGEO - Rapid prototyping using synthetic calcium phosphate
Maxilla prototype in Si powder (not biocompatible)
INGEO - Rapid prototyping using transparent resin
Mandible sectors in transparent resin (16 micron layer)
INGEO - Rapid prototyping using SI500 yellow opaque resin
Mandible prototype in SI500 yellow opaque resin (100 micron layer)
INGEO - Rapid prototyping using SI500 yellow opaque resin
Mandible prototype in transparent resin with included tooth
INGEO - Rapid prototyping using SI500 yellow opaque resin
Maxilla prototype in transparent resin with two included teeth

For further informations about Rapid prototyping, please contact PhD Luigi Paracchini, phone number +39 0321 921654 (during office hours), or send an email to info@ingeosnc.it


 

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