How 3D Systems’ Medical Modeling Is Changing the Operating Room for the Better

Originally published on 3dprint.com. By MERITXELL GARCIA SEIN-ECHALUCE

During the recent 3D Systems’ 2014 Investor & Analyst Day, one of the key issues addressed was the new frontiers in medical technology. At 3D Systems, healthcare appears to be the fastest growing market. The med-1management team stated its plans to build up its leadership in this field. The company plans to invest and expand its virtual surgical planning (VSP®) capabilities, broaden its range of implants and surgical tool manufacturing and develop new personalized medical devices, such as the recently introduced bespoke scoliosis brace.

In April, 3D Systems announced the acquisition of Medical Modeling, a leading provider of personalized surgical treatments and patient specific medical devices, including virtual surgical planning (VSP®). The VSP is a service-based approach to personalized surgery that combines expertise in medical imaging, surgical simulation and additive manufacturing. It allows for planning maxillofacial surgical procedures in a virtual environment and transferring that plan to the patient using innovative models, templates and surgical guides manufactured with 3D printers. Recently, it was used by Dr. Oren Tepper, Assistant Professor of Surgery at New York’s Montefiore Medical Center and a pioneer in virtual surgical planning. He performed surgery on a 3-week-old girl named Jayla Vargas who had difficulty breathing due to her tiny jaw. Traditionally, in such cases, she would have had to wait 6 years until she was large enough for the operation. However, with the help of VSP technology, Dr. Tepper successfully fixed Jayla’s jaw.

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At the Investor & Analyst Day, Dr. Oren Tepper was the guest speaker and he discussed the current uses and future applications of 3D printing in plastic surgery. Dr. Oren Tepper explained how technology is important in plastic surgery as creativity and innovation are involved in building, restoring and renovating the human body. Therefore, practitioners embrace this technology. Over the last several years, training and skills have been the key points in technical innovation related to plastic surgery. Advanced techniques have been used and cutting edge technology has been incorporated. For the moment, all of these advancements are focused on the operating room itself. Nonetheless, this technology is bringing greater planning and precision to operating rooms, enabling surgeons to perform successful operations that were previously impossible.

At the moment, 3D Systems and Medical Modeling has had a tremendous impact on bone reconstruction, but it is still a relatively small impact in the field. The untapped potential, especially in soft tissue reconstruction, is enormous.

“This technology eliminates surprises, minimizes complications and improves the precision of surgery.”

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According to the doctor, the first real advancement was the CT scanner, which allowed plastic surgeons to look at bodies via the CT scans. Next, the skull was 3D printed so it could be used as a reference. The process started building stereolithographic models of the skulls so it was possible to study them in any direction and to practice surgery. That was the first generation, just printing the existing anatomy of the patient. Now, it isMoney & Medicine possible to plan a surgery on a computer for surgical simulation. Therefore, surgeons can move the bone structures where they want them to be and they can develop on the computer and 3D print guides and jigs which they sterilize and bring to the operating room.

The first study about virtual surgical planning and printing was published 5 years ago. Regarding facial fractures, Dr. Tepper used an example at the conference of a lower jaw fractured in multiple pieces, on a young woman named Jayla. Due to limited exposure of the surgeon and the lack of reference points, it was difficult to put the jaw back together. The phases to follow during the process of reconstruction are:

  • Phase 1. Virtual planning: Reduce fracture and establish occlusion on the computer.
  • Phase 2. Modeling: Create jigs and guides that can be taken to the operating room.
  • Phase 3. Surgering. Place the 3D printed jigs on the patient in the operating room and use them to put the facial fractures together.
  • Phase 4. Analysis: Achieve what doctors have automatically set out to do surgically.

Regarding Jayla’s operation, Dr. Tepper emphasized that the procedure used was safer and cheaper than the traditional practice, a tracheostomy, which is a surgically created opening in the windpipe to allow proper breathing. However, virtual surgical planning is only used on a small percentage of operations today. When asked about the challenges he faced and the solutions that he came up with, Dr. Tepper highlighted four reasons why 3D printing was so useful to him in the operating room:

  • The device size. He wasn’t sure if the device was small enough that it would fit under the lower jaw but this technology solved that problem.
  • The underdevelopment of the patient’s bone. Jayla’s bone was so under developed that he needed to place the device exactly at the same parallel vector. Again, thanks to this computer technology he could perfectly do just that.
  • The critical structures. The lower jaw is not just simply made of bone. Thanks to the computer, it was possible to identify the different structures and stay away from those critical structures.
  • The bone width. This technology allowed him to predict the size of the bone so he knew exactly where to place the device.

Dr. Tepper believes in the technology’s future growth potential as it will make the existing infrastructure better and faster and it will represent a tremendous opportunity in expanding markets. At the moment, there is no communication between plastic surgeons and 3D printing companies. On the contrary, it is an opportunity for real time communication so that companies like 3D Systems could have a role in the operating room. Dr. Tepper affirmed that surgeons will one day look back on non-VSP procedures as crude and primitive.

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St. Basil’s Cathedral on a ProJet® 4500

Visit St. Basil Cathedral from the safety of your desk.

Visit St. Basil Cathedral from the safety of your desk.

Russia’s famous St. Basil’s Cathedral. Printed on a 3D Systems ProJet® 4500. How does it compare to the real thing?

To learn how we can help you with your next project, don’t hesitate to request a quote. We’ll help make your ideas a reality.

 

Objex Unlimited 3D Printing Studio
Toronto’s 3D Printing and 3D Service Experts

Objex Unlimited is your resource for everything 3D.

We take great pride in the services we provide, and will find the best 3D printing solution for you.
We will work with you to complete your project and reach your goals ahead of schedule.

We offer a variety of 3D printers3D scanners and 3D software, and will work with you to find the best solution for your needs. We are an authorized reseller of 3D SystemsArtec Group, LMI TechnologiesGeomagic and Agisoft 3D products.

Our talented and diverse staff deliver high-quality, industry-leading results.
Our commitment is to fulfill your project needs within budget and on-time.

TELL US ABOUT YOUR NEXT PROJECT

 

Guardian Lion (Foo-Dog) Statue

Guardian Lion Statue

Guardian Lion Statue. Printed on a ProJet® 660Pro by Objex Unlimited.

Design

This model was created completely from scratch by one of our Objex designers, Craig Reid. Using ZBrush and some reference photos, the statue’s geometry is sculpted from a sphere using pulling and carving techniques, much like sculpting clay.

2014-07-23 Craig's Lion Statue (1 of 25)

Print

We chose to print the Guardian Lion model on the 3D Systems ProJet® 660Pro, a type of ColorJet 3D printer. ColorJet Printing (CJP) involves two major components: core and binder. Core material is spread in thin layers over the build platform with a roller. After each layer of core material is spread, color binder is selectively jetted from inkjet print heads over the core layer, causing the core to solidify. The build platform lowers with each subsequentlayer of core and binder until the model is complete.

The advantage to using the ProJet® 660Pro for this particular print is the ability to print in full photo-realistic colour. The 660Pro utilizes the full CMYK colour spectrum, printing true black for the most realistic colour representation. This kind of colour detail is only possible on a ColorJet Printer.

To learn how we can help you with your next project, don’t hesitate to request a quote. We’ll help make your ideas a reality.

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The Bearded Dragon

Bearded Dragon. Printed on ProJet 4500 by Objex Unlimited.

Bearded Dragon. Printed on ProJet 4500 by Objex Unlimited.

Design

This model was created completely from scratch by one of our Objex designers, Craig Reid. Using ZBrush and some reference photos, the lizard’s geometry was sculpted from a sphere using pulling and carving techniques, much like sculpting clay.

Bearded Dragon 2 - Objex Unlimited

Print

We chose to print this Bearded Dragon model on the 3D Systems ProJet® 4500, a type of ColorJet 3D printer. ColorJet Printing (CJP) involves two major components: core and binder. Core material is spread in thin layers over the build platform with a roller. After each layer of core material is spread, color binder is selectively jetted from inkjet print heads over the core layer, causing the core to solidify. The build platform lowers with each subsequentlayer of core and binder until the model is complete.

There are two major benefits to using the ProJet® 4500 for this particular print. First, the obvious advantage in printing in full-color. The ProJet 4500 utilizes up to a million colours, or the full CMY colour spectrum. All colour details are easily textured on, enabling complex, realistic patterns, only possible on a ColorJet Printer. Second, the durability of the plastic. This model has many fine details such as the thorns and scales. The plastic allows the fine details to remain intact coming out of the printer, whereas many of these details would likely break-off on other powder printers.

Red Bearded Dragon - Objex Unlimited

We also printed him in red!

To learn how we can help you with your next project, don’t hesitate to request a quote. We’ll help make your ideas a reality.

 

Objex Unlimited 3D Printing Studio
Toronto’s 3D Printing and 3D Service Experts

Objex Unlimited is your resource for everything 3D.

We take great pride in the services we provide, and will find the best 3D printing solution for you.
We will work with you to complete your project and reach your goals ahead of schedule.

We offer a variety of 3D printers3D scanners and 3D software, and will work with you to find the best solution for your needs. We are an authorized reseller of 3D SystemsArtec Group, LMI TechnologiesGeomagic and Agisoft 3D products.

Our talented and diverse staff deliver high-quality, industry-leading results.
Our commitment is to fulfill your project needs within budget and on-time.

TELL US ABOUT YOUR NEXT PROJECT

Spectacular Savings on Geomagic Products!

For a limited time, Objex Unlimited is offering special deals on Geomagic software. Find out more below and take advantage of our exciting promotions today!

Promotions feature:

  • Geomagic Capture®
  • Geomagic Wrap®
  • Geomagic Freeform®
  • Sense™
  • CubePro™
  • and more!

1. Professional Designer Package – Save 24%!

Ready to elevate your design experience! With 3D Systems, and this new promotion, getting from scan-based design to print has never been easier. This package comes with Geomagic Capture for Wrap and the new CubePro Trio! Scan, design and print right at your desk.

2. Geomagic Capture for Wrap – Save 25%!

Geomagic Capture for Wrap is our newest offering for our scan-based design product line, but it’s only for a limited time! Take advantage of our Capture scanning device paired with the power of auto surfacing and design capability of Geomagic Wrap that will ramp up your design process and help get to market faster!

3. Multi Year Maintenance

Whether you are currently enjoying our maintenance program, or have not renewed recently and want to come back, we have a great deal for you! Purchase 2 years maintenance at 10% off, or purchase 3 years maintenance and qualify for 20% off.  Continue to receive free upgrades, access to our technical support team and more!

4. Starter Scan-Based Design Package – Save 21%!

Whether you’re just getting started with scan-based design, or want to unleash the creative talent of one of your teammates, this package gives you the tools you need to get going. It comes with Sense, Geomagic Design and a Cube3D Printer. Scan with confidence, utilize our user friendly CAD platform, and print on your new Cube 3D printer in just a few steps. It’s that easy.

5. Special pricing on Capture for Wrap, Freeform and Touch – Save 20%!

Unleash the power of voxel based modeling with the power of haptic feedback by combining Capture for Wrap with Geomagic Freeform. This package comes with two hardware devices, our blue light scanner and the Touch haptic device. It also includes first year maintenance which provides additional hardware support along with access to technical support and more.

6. Special pricing on Freeform Plus and Touch X and Studio – Save 38%!

Take your manufacturing to a new level. Freeform Plus and Touch X provide the tools you need to make models ready for any type of manufacturing process you currently use, and speed up the process to get you there. Add the power of scanning to your workflow to bring in your physical design and improve on it in minutes.


3D Systems Bespoke Technology Receives International Design Excellence Awards Recognition

– 3D printed hybrid Ekso Bionics robotic exoskeleton design awarded Bronze in the Social Impact Category

– Bespoke Braces given honorable mention in Professional Equipment category

3D Systems

3D Systems (NYSE:DDD) announced today that two of its Bespoke design applications have been awarded by the 2014 International Design Excellence Awards (IDEA) from the IDSA and Core77. Both the 3D printed personal Ekso robotic exoskeleton and Bespoke Braces for hand and wrist were recognized, with the Ekso being awarded Bronze in the Social Impact category.

Recognizing excellence in all areas of design enterprise, these Design Awards celebrate the richness of the design profession and its practitioners. By recognizing the design inspiration of 3DS’ personalized medical device teams, the awards highlight the rapid progress being made in personalized healthcare for a variety of medical industries by 3DS.

“3D printing and scanning are allowing massive steps forward in the field of custom-designed braces that reflect and support a patient’s unique form,” said Andy Christensen, Vice President of Personalized Surgery and Medical Devices, 3DS. “The work and research being done by our teams represent the cutting edge in patient-specific treatments and it is satisfying to see that work being recognized for the design excellence that results.”

Tad Toulis, IDSA, 2014 IDEA Jury Chair, said “This year’s IDEA jury had a fairly audacious task: judging more than 2,000 entries. We saw a lot of design work that any designer would have been inspired by. Your work demonstrated the kind of creativity and passion the jury believed represents the best our profession can aspire to. Congratulations on your win!”

Bespoke Braces for hand and wrist, currently in its pilot phase, is a first-of-its-kind medical solution to scan, design, and print custom hand and wrist braces. In the Bespoke Braces process, a patient’s arm is scanned and data is transmitted to cloud-based servers where a brace design, customized by the patient and clinician, is created to match the shape of the patient’s individual anatomy. Each brace is then 3D printed using 3DS’ selective laser sintering (SLS) technology for optimal comfort, flexibility and durability. The Bespoke Braces system is comprised of an arm scanner, an iPad app, cloud software, a network of 3D printers, and four revolutionary arm brace designs. This service has recently been expanded to include custom scoliosis braces for children and young adults.

“This product is a strong example of when customization can be leveraged to its true potential, delivering an experience that is integrated, personal and strong application of additive manufacturing processes.” – Core 77 Jury

The robotic exoskeleton announced by 3DS in February 2014 is the first-ever 3D printed hybrid robotic exoskeleton robotic suit, created in collaboration with Ekso Bionics. To create a perfect fit for Amanda Boxtel, the paraplegic patient, engineers scanned the contours of Amanda’s thighs, shins and spine and created a personalized three-dimensional base to form the shape of the required assemblies. Sophisticated mechanical actuators and controls, manufactured and provided by Ekso Bionics, were then integrated with the more fluid components that were 3D printed from the customized scans to create the first ever bespoke suit. View Amanda’s exoskeleton in action here.

To find out more about 3DS’ vision of personalized surgery and medical devices, visit: http://www.3dsystems.com/solutions/healthcare

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About 3D Systems

3D Systems is a leading provider of 3D printing centric design-to-manufacturing solutions including 3D printers, print materials and cloud sourced on-demand custom parts for professionals and consumers alike in materials including plastics, metals, ceramics and edibles. The company also provides integrated 3D scan-based design, freeform modeling and inspection tools and an integrated 3D planning and printing digital thread for personalized surgery and patient specific medical devices. Its products and services replace and complement traditional methods and reduce the time and cost of designing new products by printing real parts directly from digital input. These solutions are used to rapidly design, create, communicate, prototype or produce functional parts and assemblies, empowering customers to manufacture the future.

Leadership Through Innovation and Technology

•3DS invented 3D printing with its Stereolithography (SLA) printer and was the first to commercialize it in 1989.

•3DS invented Selective Laser Sintering (SLS) printing and was the first to commercialize it in 1992.

•3DS invented the Color-Jet-Printing (CJP) class of 3D printers and was the first to commercialize 3D powder-based systems in 1994.

•3DS invented Multi-Jet-Printing (MJP) printers and was the first to commercialize it in 1996.

Today its comprehensive range of 3D printers is the industry’s benchmark for production-grade manufacturing in aerospace, automotive, patient specific medical device and a variety of consumer, electronic and fashion accessories.

More information on the company is available at www.3DSystems.com.

ABOUT THE CORE77 DESIGN AWARDS

Recognizing excellence in all areas of design enterprise, the Core77 Design Awards celebrates the richness of the design profession and its practitioners. For our fourth year, we present 17 categories of entry, providing designers a unique opportunity to communicate the intent, rigor and passion behind their efforts. From client work to self-initiated projects, entrepreneurial to pro-bono engagements, we embrace a wide diversity of design enterprise: commercial, cultural, social, environmental, or discursive. We welcome projects in all these spheres and honor the time, effort and quality of the endeavors, no matter their provenance.

ABOUT CORE77

Since 1995, Core77 has served a devoted global audience of designers ranging from students through seasoned professionals. Core77 publishes articles, discussion forums, and an extensive event calendar in addition to hosting portfolios, job listings, and a database of design firms, schools, vendors and services. Core77 also provides a gathering point for designers and enthusiasts alike by producing design competitions, lecture series, parties, and exhibitions.

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3D Systems Ranks 13th in Forbes 100 Most Innovative Growth Companies

3D Systems (NYSE:DDD) announced on Tuesday July 8th, that the company ranked number 13 in Forbes’ list of the most innovative companies with a market capitalization under $10 billion. This distinguished ranking singles out the top 100 companies that demonstrated continued growth through innovation.

news-release-rock-hill_11

The Forbes list is generated annually by measuring an “innovation premium” using a proprietary formula in collaboration between Forbes and Credit Suisse.

“Ranking 13 on this distinguished Forbes’ list of the most innovative companies underscores our commitment to accelerated innovations that advance 3DPRINTING 2.0 targets,” said Avi Reichental, President and CEO, 3DS. “We are committed to making 3D printing affordable, fast and capable of meeting the most demanding performance requirements for a wide range of industrial manufacturing cases, personalized healthcare applications as well as desktop design and consumer needs.”

3DS is the leading provider of the most comprehensive and affordable 3D printing based products and services that are empowering individuals and transforming industries through constant innovation. 3DS is committed to expanding the realm of advanced manufacturing capabilities that enable practical and scalable digital craftsmanship.

Learn more about 3DS’ commitment to manufacturing the future today at www.3dsystems.com.


About 3D Systems

3D Systems is a leading provider of 3D printing centric design-to-manufacturing solutions including 3D printers, print materials and cloud sourced on-demand custom parts for professionals and consumers alike in materials including plastics, metals, ceramics and edibles. The company also provides integrated 3D scan-based design, freeform modeling and inspection tools and an integrated 3D planning and printing digital thread for personalized surgery and patient specific medical devices. Its products and services replace and complement traditional methods and reduce the time and cost of designing new products by printing real parts directly from digital input. These solutions are used to rapidly design, create, communicate, prototype or produce functional parts and assemblies, empowering customers to manufacture the future.

Leadership Through Innovation and Technology

•3DS invented 3D printing with its Stereolithography (SLA) printer and was the first to commercialize it in 1989.

•3DS invented Selective Laser Sintering (SLS) printing and was the first to commercialize it in 1992.

•3DS invented the Color-Jet-Printing (CJP) class of 3D printers and was the first to commercialize 3D powder-based systems in 1994.

•3DS invented Multi-Jet-Printing (MJP) printers and was the first to commercialize it in 1996.

Today its comprehensive range of 3D printers is the industry’s benchmark for production-grade manufacturing in aerospace, automotive, patient specific medical device and a variety of consumer, electronic and fashion accessories.

More information on the company is available at www.3DSystems.com.

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A Perfect Match for High Precision Dental Model Production: ProJet® 3510 and 3Shape

3D Systems announced on May 29, 2014 that its ProJet® 3510 MP 3D printer and proprietary VisiJet®Pearlstone dental material have been verified by 3Shape for prosthodontic dental model production. Verified and integrated with 3Shape’s Model Builder software, 3DS’ ProJet 3510 MP is a proven solution for manufacturing prosthodontic dental models with accuracy, precision and push-button simplicity.

3Shape affirms that the ProJet® 3510 MP 3D printer and proprietary VisiJet®Pearlstone dental material:

  • Are the first and only 3D printer solution verified by 3Shape for ultra-high fidelity prosthodontic dental model production
  • Provides seamless integration with 3Shape Model Builder software for 3D model production with high accuracy, precision and ease of use
  • Offers online access to 3DS’ production facilities for on-demand model production.

“Since we installed our ProJet 3500 series printer with Pearlstone we have printed thousands of models with incredible consistency and accuracy.  It integrates seamlessly into the 3Shape digital workflow for the TRIOS intraoral scanner, and the post-processing labor involved with this printer is minimal,” said Rob Nazzal, CEO of Custom Automated Prosthetics. “Technicians are comfortable working with these models since they look and feel like stone, and the doctors love the superior fit of the all-digital restorations.”

The ProJet 3510 MP is part of a comprehensive, personalized digital thread for dental model production, starting with models designed in Model Builder software direct from intraoral scans or physical impression scans, and output seamlessly on the ProJet 3510 MP with VisiJet Pearlstone material. The VisiJet Pearlstone dental material is available in both a Matte Plaster and Glossy print mode with a 30 micron layer thickness, an average accuracy of 50 microns and a stone-like finish.

3DS has also integrated its production services capabilities into the 3Shape software solution, so that Model Builder users without access to a ProJet 3510 MP can simply select 3D Systems from a pull down manufacturing output menu in the Model Builder software and order dental models from 3DS production facilities. 3DS will print the models on the ProJet 3510 MP direct from the Model Builder file and ship to the customer.

“We have performed all of the integrated design work to ensure seamless integration with 3Shape’s Model Builder software as part of a comprehensive digital thread,” said Lee Dockstader, Vice President Business Development, 3DS.  “No other 3D printer has crossed this threshold and we are proud to announce our verification with 3Shape, as well as our production services capabilities to offer a proven dental model solution for Model Builder customers worldwide.”

“3D Systems’ ProJet 3510 MP and Pearlstone materials produce accurate, precise and high fidelity prosthodontic dental models direct from 3Shape’s Model Builder software, providing our customers with a complete digital workflow,” said Rune Fisker, Vice President Product Strategy, 3Shape. “We are also pleased to add 3D Systems as a manufacturing output provider in our integrated software solution so our customers can order dental models direct from 3D Systems through our software.”

Objex Unlimited carries and services both the ProJet 3510 MP and VisiJet Pearlstone material. For more information, contact us or get a quote.

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About 3Shape

3Shape is a Danish company specializing in the development and marketing of 3D scanners and CAD/CAM software solutions designed for the creation, processing, analysis and management of high-quality 3D data for application in complex manufacturing processes. 3Shape envisions the age of “full digital dentistry,” and its 400 employees, including more than 175 developers provide superior innovation power toward reaching this goal. 3Shape’s flexible solutions empower dental professionals through automation of real workflows, and its systems are applied in thousands of labs in more than 100 countries worldwide, putting 3Shape technologies at the peak of the market in relation to units produced per day by dental technicians. With TRIOS®, 3Shape now brings its vast expertise and innovation power directly to dentists. 3Shape boosts its first-line distributor support network with a training and support force of over 50 in-house experts placed in 6 support and service centers strategically located around the globe. 3Shape is a privately-held company headquartered in Copenhagen, with the market’s largest team dedicated to scanner and software development for the dental segment based in Denmark and Ukraine, production facilities in Poland, and Business Development & Support Offices at several locations in Europe, in North America, Latin America and in Asia. For further information regarding 3Shape, please refer to www.3shapedental.com. Visit us on www.facebook.com/3shape, or view our mobile site onm.3shapedental.com.

About 3D Systems

3D Systems is a leading provider of 3D printing centric design-to-manufacturing solutions including 3D printers, print materials and cloud sourced on-demand custom parts for professionals and consumers alike in materials including plastics, metals, ceramics and edibles. The company also provides integrated 3D scan-based design, freeform modeling and inspection tools and an integrated 3D planning and printing digital thread for personalized surgery and patient specific medical devices. Its products and services replace and complement traditional methods and reduce the time and cost of designing new products by printing real parts directly from digital input. These solutions are used to rapidly design, create, communicate, prototype or produce functional parts and assemblies, empowering customers to manufacture the future.

Leadership Through Innovation and Technology

  • 3DS invented 3D printing with its Stereolithography (SLA) printer and was the first to commercialize it in 1989.
  • 3DS invented Selective Laser Sintering (SLS) printing and was the first to commercialize it in 1992.
  • 3DS invented the Color-Jet-Printing (CJP) class of 3D printers and was the first to commercialize 3D powder-based systems in 1994.
  • 3DS invented Multi-Jet-Printing (MJP) printers and was the first to commercialize it in 1996.

Today its comprehensive range of 3D printers is the industry’s benchmark for production-grade manufacturing in aerospace, automotive, patient specific medical device and a variety of consumer, electronic and fashion accessories.

More information on the company is available at www.3DSystems.com.

 

(image caption: Prosthodontic dental model printed on 3D Systems’ ProJet 3510 MP with VisiJet Pearlstone material shown with 3D printed wax-ups made on 3D Systems’ ProJet 1200 with VisiJet FTX Green material.)

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