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Disposable Instruments Create Value in Medical Applications'
Knee replacements are one of the most common surgeries. Today, a large set of instruments and measurement guides are necessary for the surgery. Operating with conventional methods is both expensive, time consuming and a straining procedure for both patient and surgeon. By using disposable instruments, the procedure can be optimized. This is how it works: Based on a Magnetic Resonance Imaging (MRI) or a Computer Tomography (CT) scan, a 3-D image of the knee is created, correcting the deformity of the knee and matching with the implant used in the surgery. Using the above information, a disposable surgical instrument is manufactured, accurate within a few millimeter tolerances indicating the exact area of cutting or drilling. The instrument is made from biocompatible PA 2200 from EOS and will be used only once with one specific patient. Martin Bullemer, Key Account Manager Medical, explains: “Disposable instruments are a true e-Manufacturing application which we can realize with means available today. It comes with benefits for patient, surgeon and hospital and is therefore a very interesting option for medical device companies.”

 

Benefit for the Patient
The patient spends less time in the operating room and has a lower anesthesia time, which reduces the risk of complications and infections. Furthermore, the implant is placed with precision, thus minimizing the risk of failure. In this way, it feels more natural and lasts longer than traditional knee replacements. And last: Because there is no need to remove too much healthy tissue or bone associated with the traditional approach, the patients can count on a quicker and less painful recovery. Therefore, they are allowed to leave the hospital quicker and return to an active lifestyle sooner.

 

Benefit for the Surgeon
The operating method with disposable instruments saves time by eliminating multiple steps that were once necessary with conventional operating methods. The patient-matched instruments allow the surgeon to make precise bone cuts. Surgical remodeling of the knee to fit the patient to the implant is not necessary any longer. Healthy bone and ligaments are saved, the implant aligns the knee perfectly. In this way, the risk of failure and complications is reduced.

 

Benefit for the Hospital
Expenses are reduced significantly. The new method helps hospitals to eliminate sterilization and stocking costs before and after each surgery associated with the traditional reusable instrument. Overall, this example shows the advantages of laser-sintering which always becomes attractive for customers when it comes to manufacture one individual piece at a time. Providing a fast and extremely flexible technology is the key for many manufacturing opportunities, which haven’t been addressed by traditional manufacturing techniques.