Abstract
The applications of Additive Manufacturing (AM) have increased extensively in the area of orthopaedics. The AM applications are for making anatomic models, surgical instruments & tool design, splints, implants and prosthesis. A brief review of various research articles shows that patient-specific orthopaedic procedures provide multiple applications areas and provide directions for future developments. The purpose of this paper is to identify the best possible usage of additive manufacturing applications in orthopaedics field. It also presents the steps used to prepare a 3D printed model by using this technology and details applications in the field of orthopaedics. AM gives a flexible solution in orthopaedics area, where customised implants can be formed as per the required shape and size and can help substitution with customised products. A 3D model created by this technology gain an accurate perception of patient's anatomy which is used to perform mock surgeries and is helpful for highly complex surgical pathologies. It makes surgeon's job accessible and increases the success rate of the operation. AM provides a perfect fit implant for the specific patient by unlimited geometric freedom. Various scanning technologies capture the status of bone defects, and printing of the model is done with the help of this technology. It gives an exact generation of a physical model which is also helpful for medical education, surgical planning and training. This technology can help to solve present-day challenges as data of every patient is different from another.
Keywords
1. Introduction
In recent years, there has been a significant improvement in additive manufacturing technologies, and researchers have explored its applications in various fields of engineering and medicine. It creates a physical model from the digital 3D model without any requirement of process planning, physical tools and dies. This technology has great capability to fabricate complex shape prototypes with a variety of materials such as nylon, polymers and even metals. It produces implants of biocompatible materials that meet structural requirements.
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,- Javaid M.
- Haleem A.
Additive manufacturing applications in medical cases: a literature-based review.
Alex J Med. 2017; https://doi.org/10.1016/j.ajme.2017.09.003
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Additive manufacturing is a type of manufacturing technology in which materials like powder, plastic or metal are deposited layer by layer to fabricate the 3D model from Computer Aided Design (CAD) model. This method is different from traditional manufacturing technology because rather than removing of material; it adds materials layer by layer. In surgical applications, this technology is used to create a model which gives a better understanding of complex pathology and anatomy of the patient. It easily produces specific custom implants and patient-specific instruments which help surgeon during the surgery of the patient.
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In biomedical engineering, orthopaedics is surgical discipline applied through various disciplines such as joint arthroplasty, ranging from trauma surgery to tumour surgery for correction of the deformity. Orthopaedic applications provide a detailed analysis of the musculoskeletal system and craniomaxillofacial surgery.
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,1
- Javaid M.
- Haleem A.
Additive manufacturing applications in medical cases: a literature-based review.
Alex J Med. 2017; https://doi.org/10.1016/j.ajme.2017.09.003
Applications of additive manufacturing give a flexible solution with quick and cost-effective production of implants and also surgical instruments with high-quality of patient-specific. AM offers multiple benefits as compared to conventional implant production methods. By 3D CAD data, patient-specific parts are produced without using any tool along with required medically compatible materials and with a high quality of accuracy and precision. It makes surgeon job easier and optimise patient's treatment with minimum unpleasant side effects. AM methods can produce individual instrument and easily manufacture various medical devices. This technology is recasting in orthopaedic care that rapidly fabricates implantable devices by the use of bioactive materials and polymer.
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In orthopaedics, AM has extensive benefit for bone ingrowths capabilities. It enables to fabricate complex metal parts of the different shape, size and design. Regarding improving lives, it has a dramatic effect on the human condition. This is helpful for both clinical environment and manufacturing method. It creates implant of spinal devices, standard knee and helpful in the development of orthopaedic implant.
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2. Generation of 3D objects by using additive manufacturing applications in orthopaedics
In orthopaedic the patient-specific analysis is essential to obtain an accurate medical imaging data of the individual patient. Magnetic resonance imaging (MRI), modern multi-row detector Computer Tomography (MDCT), Computer tomography (CT) scan, X-rays and 3D scanners provide an accurate, fast, high-resolution data and easily prepare a 3D view of patient's anatomy. AM convert the digital medical image into a 3D physical model. This conversion takes place in three steps discussed in Table 1.
Table 1Generation of 3D objects by using additive manufacturing applications.
S No | Steps used | Description | References |
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1 | Image acquisition |
| Wong 6 ; Souzaki et al8 ; Verma et al9 ; Lal et al
Customized iliac prosthesis for reconstruction in giant cell tumour: a unique treatment approach. J Clin Orthop Trauma. 2016; https://doi.org/10.1016/j.jcot.2016.10.001 10
Inserting pedicle screws in lumbar spondylolisthesis – the easy bone conserving way. J Clin Orthop Trauma. 2017; https://doi.org/10.1016/j.jcot.2016.11.010 |
2 | Image post-processing |
| Jardini et al 11 ; Trace et al12 |
3 | 3D printing |
| Javaid and Haleem 1 ; Martelli et al
Additive manufacturing applications in medical cases: a literature-based review. Alex J Med. 2017; https://doi.org/10.1016/j.ajme.2017.09.003 13 |
The data is captured by advanced medical imaging, making the diagnosis reliable and more manageable.
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,- Vaishyaa R.
- Vijaya V.
- Krishnan B.M.
- Agarwala A.K.
Fallacies of CT based component size prediction in total knee arthroplasty – are patient-specific instruments the answer?.
J Clin Orthop Trauma. 2017; https://doi.org/10.1016/j.jcot.2017.11.001
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3-D reconstruction images from these scanning technologies provide superior visualisation. This provides better surgical management and accurate diagnosis. These scanning technologies give 3D pictures displayed on a computer screen which cannot affect the perception of a physical model for complicated cases. For this, it is necessary to print these 3D models by the additive manufacturing technologies for the complete understanding. These 3D printed models provide better information to the surgeon. Before printing it is necessary to prepare DICOM which is extracted from the medical imaging and then convert it into STL format to complete the printing process by 3D printing machines.1
- Javaid M.
- Haleem A.
Additive manufacturing applications in medical cases: a literature-based review.
Alex J Med. 2017; https://doi.org/10.1016/j.ajme.2017.09.003
3. Applications of additive manufacturing in orthopaedics
Additive manufacturing provides tremendous development in manufacturing field and now explore its applications in various medical fields. The 3D printed model's first goal is to resemble the cases in the clinic and give a detailed overview to the surgeon. The principal application of this model is for the testing procedure in advance as it provides a feeling of the mechanical response of real bone to the surgeon. The operation can also be performed on the 3D model to examine and visualise before performing actual surgery. Table 2 describes various applications of additive manufacturing in orthopaedics.
Table 2Applications of Additive Manufacturing in Orthopaedics.
S No | Applications | Description | References |
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1 | Anatomic models for the planning of surgery |
| Pacione et al 16 ; Vaish and Vaish17 ; Pietrabissa et al
3D printing and its applications in orthopedics. J Clin Orthop Trauma. 2018; https://doi.org/10.1016/j.jcot.2018.02.003 18 ; Souzaki et al8 |
2 | Cost-effectiveness for orthopaedics |
| Trace et al 12 ; Salmi et al19 ; Javaid et al20 ; Kumar et al4 |
3 | Surgical guides |
| Yap et al 21 ; Wong et al22 ; Javaid and Haleem1
Additive manufacturing applications in medical cases: a literature-based review. Alex J Med. 2017; https://doi.org/10.1016/j.ajme.2017.09.003 |
4 | Patient-specific instruments |
| Trace et al 12 ; Negi et al2 ; Han et al23 |
5 | Bone tissue engineering |
| Zein et al 24 ; Peltola et al25 |
6 | 3D-printed custom implants |
| Jardini et al 11 ; Wong et al7 |
7 | Bone Defect |
| Han et al 23 ; Pietrabissa et al18 |
8 | Improved patient care |
| Salmi et al 19 ; Boonen et al26 |
9 | Precision for surgeons |
| Yap et al 21 ; Choi and Kim3 |
10 | Weight reduction of implants |
| Wang et al 27 ; Peltola et al25 |
11 | Osteochondral and Chondral defect |
| Boonen et al 26 ; Pacione et al16 |
12 | Education and surgical training |
| Mahmoud et al 28 ; Sodian et al29 ; Hurson et al
Pediatric cardiac transplantation: three-dimensional printing of anatomic models for surgical planning of heart transplantation in patients with univentricular heart. J Thorac Cardiovasc Surg. 2008; 136: 1098-1099 30 |
The applications of additive manufacturing in orthopaedic surgery provide reproducible, safe and reliable models that improve patient outcomes and reduced operating time as compared to traditional surgical techniques. This technology can work successfully for preoperative planning, education and custom manufacturing. For Custom manufacturing applications it is used for prosthetics, surgical guides and implants. 3D printed models of anatomy have assisted in the education of students, trainees, patients and surgeons. Surgeon and doctors can use 3D printed bone model for practising of surgery and explain the patient or students about the surgery. It also has potential to increase the number of tools for the surgeon and easily undertake the redesigning. It becomes a valuable tool that has an impact on every area of medicine. Surgeons can now develop new tools and techniques for surgical procedures.
4. Discussion
Additive manufacturing easily develops personalised prostheses and implants which is more valuable in the field of orthopaedics. This technology can rapidly fabricate implants of any desired shape and also used for the production of size-controllable micro-pore structures. For research and development of orthopaedic implants, it is promising. Its applications are enhanced in medical and solve various problems regarding this field. 3D printed physical model can help surgeons to have a visual and tactile understanding of the patient-specific pathology and anatomy. Surgeon and patient can now understand easily about the medical conditions with a real 3D physical model. It increases the patient satisfaction and safety. It is helpful to give training to the doctor and medical students for better understanding of the various types of fractures. Customised and high-quality implants with a wide variety of material are quickly built to meet the required standard in orthopaedics with minimum risk. By changing the properties of the raw material, this technology tends to reduce the weight of the implant. It gives a flexible solution with the quick and cost-effective production of various medical tools and devices.
5. Limitations and future scope
The cost of additive manufacturing technology is very high that includes software, hardware, skilled human resources for operating, maintaining as well as the cost of printing materials. AM creates implants with high cost and also required a high cost of designing. Another limitation of this technology is the timescale physical model production. It is variable that depends on the complexity and size of the model. Image acquisition and data processing take time. Then for the fabrication of model, it depends on the types of technologies of additive manufacturing. The machines take 24 h to complete the printing process of the standard model. Model printed by this technology has limited application. In some cases, it is not implemented and can only be used for a better understanding of the actual surgery. In orthopaedics, implants printed by AM technology are fabricated layer by layer and bonded together. Sometimes mechanical strength that the user required is not achieved and thus makes it unsuitable for long-term use.
In future, 3D-printed custom implants can be a suitable adjunct for the patients. Artificial bone consist mechanical properties that are similar to human bone. It opens a reconstruction option that helps orthopaedic surgeons, radiologists, and implant companies. By using this technology surgeon take help to facilitate customised patient treatments of their patients. It presents new opportunities in orthopaedics for exact generation of the physical model which is also suitable for education, surgical planning and training. This technology can solve present-day challenges in medical because, in medical, the data of every patient is different from each other. Among different care providers, it provides seamless communications. This can give elastic properties and strength close to the actual bone. It produced the implant of required shape and size before the actual surgery that improves quality of surgery of the patient. It helps to impart an enhanced long-term quality of life of the patient.
6. Conclusion
Additive manufacturing is a type of manufacturing process that produces a 3D object from the digital model. Based on CT and MRI, the bone 3D image can be reconstructed, and then obtains a bone prototype by layer by layer technique and play an effective role in medical as well as in orthopaedic surgery. This is helpful for surgical design, teaching and presentation of complex surgeries. By using reverse engineering technique of AM, a missing part of the bone is created. The popularity and advancement of this technology are for implant design and fabrication, tissue engineering, preoperative surgical planning and even in training of doctors and surgeon. It produces an implant of the individual patient at a fast pace which fits better as compared to standard implant manufacturing by the traditional manufacturing process. The true physical model produced by this technology allows the surgeon to have a better understanding. Production of scaffolds for bone tissue engineering is another application of this technology which is used for the fabrication of structurally sophisticated bio-scaffolds. 3-D bio-scaffolds are designed as per the need of clinical applications with significant mechanical and biological properties. 3D printed surgical guides simplify the surgery that reduces operative time and makes surgery precise. CT and MRI scan are used to capture data, and additive manufacturing technologies are used to make surgery successful.
Conflict of interest
None.
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Article info
Publication history
Published online: April 23, 2018
Accepted:
April 17,
2018
Received in revised form:
April 9,
2018
Received:
February 20,
2018
Identification
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