Speed and accuracy are compatible in today's advanced production of implants for knee surgery.

Decreasing the time from design to market are new manufacturing methods such as direct digital manufacturing (DDM), a direct from CAD data technique whereby 3D plastic or metal parts are built layer by layer. The "e-machines" may use electron beams to melt compounds in fabrication.

A term coined by the Society of Manufacturing Engineers, DDM provides rapid manufacturing methods popular with medical device manufacturers. For instance in orthopedics, CT scan data frequently becomes the basis of designs for fabrication of patient custom knee implants. Custom implants using biocompatible metals are built to exactly match the shape of patient's bones.
"3D printing is becoming an increasingly popular method for design and direct digital manufacturing where customization and quick turnaround are important," comments Jon Cobb, VP/GM for Dimension 3D Printing Group, who acknowledges that the medical device field is using 3D printing for custom implants and jigs. The firm is located in Eden Prairie, MN.

How does it work? A patient receives a CT scan per recommendations of the firm so that a complete "picture" can be rendered. The CT images are uploaded to the scanning center using a secure Web server. The images are imported from the server to the proprietary software that generates the spatially rendered surfaces, and the implant also provides for complete alignment with minimal bone cutting and cortical rim coverage--a feature not possible with off-the-shelf implants.

The Dimension machines help support a business model of just-in-time manufacturing, eliminating the need for maintaining large inventory. Once the implants are made and sterilized, they can be distributed. The total time to market is six to eight weeks.

Learn more at www.dimensionprinting.com

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