Implant design, prototyping & simulation

Surgical tooling for use in theatre comes at a price, however using 3D printing we can provide these tools suitable for simulation at a fraction of the cost. These tools can be used to create a low-cost embedded lab for clinicians to plan, simulate and educate around surgical procedures. We have a skilled design team ready to take your ideas from draft to prototype. With our in-house printing services we are able to provide prototyping in a wide range of materials suitable for your application. Providing a library of models gives us the unique ability to test your implant design with a variety of anatomies and pathologies, initially in a virtual space and then in the lab.

Surgical guides

We can provide sterilisable patient specific guides to improve drilling and cutting accuracy for surgical procedures. Designs can be made to your specification and provided in a sterilisable material (PA-12 Nylon – ISO13485 compliant). Using patient specific guides not only improves cutting and drilling accuracy but can reduce time spent performing the procedure and an overall time saving in theatre. Pre-determined axis or planes can be established outside of theatre time and directed in the best possible orientation.

3D Printing for surgical tooling

If you would like to explore an idea for a new tool or improvement on an existing piece of tooling – we can provide the design, prototyping and simulation space to test that idea. Our bespoke tooling service can be used to both suit the clinician and the patient; Ergonomic tooling can help to reduce surgical fatigue and the interaction with tooling more comfortable. For a patient with complex anatomy standard tooling may not be adequate and a bespoke solution could be necessary. Our experience with anatomical segmentation means that we can provide tooling completely customised to the patient.

 

Clinical research

Clinical procedures are grounded in robust clinical studies we can supply anatomical models of specific pathologies for research projects to suit all applications. Our models are accurately reproducible and are available at a fraction of the cost of cadavers, which can be used only once. Additionally, we are able to model any pathology required – for example if a particular anatomy cannot be found clinically.

Procedure specific planning solutions

Femoro-acetabular Impingement:

Using our state of the art dual colour 3D printing technology, we are able to highlight areas of impingement (Pincer, CAM and combined) for the surgeon to assess the patient for appropriate treatment. To achieve this, data taken from a CT scan is represented in a 3D virtual space where our on-site biomedical engineer is able to fit a best-fit-sphere, accounting for cartilage, at the joint centre of rotation. Bony structures left outside of the sphere are then considered for impingement correction.

Procedure specific planning solutions

Planning for Total Hip Replacement (THR):

Acetabular and femoral deformities can be better understood and explained more effectively to the patient when visualised in 3D. Having a 3D model printed in an operable material allows the clinician to establish a measured strategy for treatment before ever entering the operation. With an on-site simulation facility our clinician’s are able to identify and fit appropriate implant types and sizes, giving the hospital notice of which implants will be needed on the day of surgery.

Our operable models allow for reaming, burring, cutting and drilling to provide a life-like response to bony structures. In cases where dynamic assessment of the joint biomechanics is required, the cartilage can be introduced to the model ensuring the correct rotation mechanics.