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Additive Manufacturing for Medical Instrumentation Paul Breedveld, Filip Jelinek, Rob Pessers, Tom Diepens

Bio-Inspired Technology Group Delft University of Technology RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


Minimally Invasive Surgery

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


Minimally Invasive Surgery

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


Muscular Hydrostatic Skeleton Systems

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


From Squid to Cable-Ring

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


From Squid to Cable-Ring

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


From Squid to Cable-Ring

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


From Squid to Cable-Ring

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


From Squid to Cable-Ring

2004: Endo-Periscope

Patented

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


Research Lines microsurgery & percutaneous (wrist, <Ø2mm) I-Flex

laparoscopy & neurosurgery (wrist, Ø2-5mm)

multi-steerable & dendritic (tentacle, Ø2-5mm)

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


Generating Stiffness

Complex & Expensive, Prone to fatigueâ&#x20AC;Ś Yet stiff!

1 DOF equals 1 Joint Strongly increased cable bending radius

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex I â&#x20AC;&#x201C; Maximizing Cable Radius

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex I â&#x20AC;&#x201C; Maximizing Cable Radius

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex I â&#x20AC;&#x201C; Maximizing Cable Radius

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex I â&#x20AC;&#x201C; Maximizing Cable Radius

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex I â&#x20AC;&#x201C; Final Design

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex I – Prototype 15 mm wide, resin-like Objet VeroBlue™ RGD840 material Printed with Objet Eden260V™ 3D printer

Drawback: Accuracy insufficient for real-scale RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex II – Manufacturing Process 5 mm wide, ceramic-filled epoxy resin EnvisionTEC® NanoCure RCP 30 Printed by micro-stereo lithography (SLA), Digital Light Processing™ (DLP) method, using Perfactory® SXGA + Mini Multi Lens rapid prototype manufacturing system Printed at 30µm resolution and 50µm layer thickness

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex II – Prototype

Drawbacks: • Reasonable accuracy • Very brittle RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex III â&#x20AC;&#x201C; Reducing Play

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex III â&#x20AC;&#x201C; Reducing Play

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex III â&#x20AC;&#x201C; Reducing Play

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex III â&#x20AC;&#x201C; Prototype

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


DragonFlex III – Prototype 5 mm wide, clear hard polymer 3D Systems Accura® 60

Printed by micro-stereo lithography using 3D Systems Viper si2™ SLA® System Printed at 75µm resolution with accuracy/error of 15µm and (theoretically) 2.5µm layer thickness

Drawbacks: • Insufficient accuracy • Brittle RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


3D Printing – Bottlenecks for fine manufacture • • • • • •

Metals still rough and unprecise Accuracy & mechanical properties of resins not OK Shrinkage & warping (“kromtrekken”, DragonFlex III) Limited list of bio-compatibe materials Removing support material difficult at small dimensions Direction of printing very important

Close collaboration between designer & manufacturer needed!

RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


3D Printing - Design Challenges

After 4000 years of circles & cilinders we now have to twist to a new design mindset RapidPro 2014 - Paul Breedveld - Additive Manufacturing for Medical Instrumentation


Additive manufacturing for medical instrumentation  
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