Printing’s Impact on Medicine – 3D Printable Casts & Prosthetics

Today we’re taking a look at the promising implications 3D printing has for the medical industry.

From bones healing faster to amputees walking again, 3D printing's healing hand is not going unnoticed. Confused about how new-age printers can help patients? 

Read on and we’ll explain all about it.

The Evolution of the Plaster Cast
The Cortex Cast

2013 saw the introduction of the ‘Cortex Cast’, a stylish, ventilated 3D printable cast invented by University of Wellington graduate Jake Evill. 

Built in 2 or more pieces and then adjoined, the patients’ limbs can be scanned and turned into a 3D model, allowing for an accurate fit. 

Currently, printers may take hours to churn out a complete plastic cast, but we can expect this time to be reduced drastically as efficiency increases in the coming years.

This experimental product will cater to individuals varying limb sizes, and in the future can be printed on site, in a hospital or clinic. The smile on a patient's face will serve as proof of witnessing a successful marriage between medicine and technology.

Available in various colors, printable casts will grow to symbolize 3D printing's low-key invasion into the fashion world. Expect Malta 3D Printing to blog about this shortly!

The Osteoid

A 3D printable cast known as the ‘Osteoid’ is helping to heal bones up to 80% faster. Created by Turkish design graduate Deniz Karasahin, the cast’s plastic, aerated structure allows for an ultrasound device to be attached to it – resulting in improved treatment for patients. 


Bulkiness, itchiness and discomfort associated with plaster casts will become a thing of the past thanks to the Osteoid’s lattice pattern and lightweight build.

 

This promising invention won the ‘A'Design Award in 3D Printed Forms and Products Design in 2013. Its full name is the ‘Osteoid Medical Cast, Attachable Bone Stimulator’, but we prefer the ‘Osteoid.’ 

The wires attached to the plastic frame (see picture above) allow for the healing pulse to be sent to the desired area, sending ultrasound waves at the touch of a button. 

With a single 20 minute daily session, the Osteoid can potentially improve healing rates by up to 80% in non-union fractures, and up to 38% in other fractures.

The Osteoid is made out of ABS (acrylonitrile butadiene styrene), a popular thermoplastic with 3D printing vendors, household goods and food containers. While it may seem like a simple design, the precise location of each air space is algorithmically calculated, and the locking mechanism (see picture below) may vary in location from case to case.

 Both the aforementioned models are more expensive than present day remedies, but offer localized healing, water-resistance, and a higher standard of environmental sustainability and aesthetics.

We can only imagine a little girl with a broken hand looking up at a doctor, smiling as she tries on her cast in her favourite colour. Small details can go a long way!

 Once 3D printing successfully infiltrates hospitals worldwide, expect to see a myriad of patients with casts in blue, red, yellow green and more!

3D Printable Prosthetics 

According to statistics collected in 2008, there are approximately10 million people across the world living with amputations (arm, elbow, shoulder, leg, knee etc.). 

Unfortunately, only a select few can even afford prosthetic limbs, as a large percentage of amputees live in developing countries. 

Skeptical about 3D printing's global influence? Well, it's a good thing Malta 3D Printing's here.

Miracles are already happening throughout the 3D printing world. Patrice Johnson, using a $500,000 3D printer owned by Ex-One, began printing prosthetic arms and lending a helping hand to people in less fortunate parts of the world.

 “Right on the border of Burma and Thailand, there are landmines like you wouldn’t believe,” Johnson said in an interview with The Atlantic.

Bravely venturing to Burma equipped with two 3D printed prosthetic arms, Johnson donated the artificial limbs and had the two lucky patients feeling comfortable within half an hour.

It’s not all blue skies, however, as Johnson points out that the main issue with 3D printed limbs lies in the attachment.  It must successfully connect to both soft tissue and bone without damaging either, whilst providing an adequate range of motion for the patient.  

Luckily, one of 3D printing’s many strengths can solve this problem. Due to the extreme level of detail 3D scanners and printers can achieve, a full scan of a patient’s intact limb would result in a precise 3D replica – one that post-print would be expected to be an exact fit on the damaged limb.

A prime example of an artificial 3D printed limb is the ‘Jaipurknee’. Pictured in the image above, the Jaipurknee claims to be one-tenth the cost of a traditional polycentric knee joint and is built to last between 3-5 years. 

With 3D printers firing on all cylinders across the globe, the number of amputees could be drastically reduced within the coming years, as people gain access to cheaper, more efficient means of limb replacement. 

The team behind Malta 3D Printing have nothing but respect for these life-changing inventions.

Cutting Edge Tech - Oculus Rift, Altergaze, 3D Doodler

Welcome back to the home of Malta 3D Printing! 

With a host of exciting 3D printing prospects on the horizon, our team of tech junkies are on constant alert for promising projects in the industry.

Today we’ll take a look at how 3D printing goes hand-in-hand with the latest virtual reality devices, as well as presenting the world’s first 3D Printing pen!

Fact: Kickstarter has helped turn all 3 of these brilliant ideas into real products!

The Oculus Rift

Essentially a portable virtual reality headset, this revolutionary project was designed by Oculus VR, and invented by Palmer Luckey. 

The Oculus Rift is aimed at transforming the way users experience media – mainly video games, but other visual media too.

The Oculus Rift uses 2 stereoscopic lenses to project a small screen in front of your eyes to a 160 degree angle (the naked eye typically sees 180 degrees), ultimately transporting your vision to a virtual reality.

You may be asking yourself, where does 3D printing fit into all of this?

The answer lies with the Oculus Rift’s inventor, Luckey, who worked on a number of low-budget augmented reality machines prior to the Oculus. These devices, many of which have remained open-source, can all be 3D printed.

The MxR (Luckey’s former associates) lab at the University of Southern California have a number of free, 3D printable versions of these 'immersive' viewers, including the VR2GO and Socket HMD (head-mounted display), which work with various smartphones.

Once fitted with the correct circuitry and software, the item transforms itself into a low-cost ‘immersive viewer.’ While these machines may eventually be brushed aside by the Oculus’ supremacy in the VR world, they have, ironically, paved the way for it to take centre stage.

One can also print a number of unofficial attachments for the Oculus Rift. These include eye-cups and adjustable focus knobs and sensor mounts, all available to print for free from thingiverse.com.

3D printing picks up where the developers left off, allowing for customers to tweak their products, resulting in an improved experience. 3D printing effectively acts as the cherry on the cake. 

The Altergaze

When 3D printing and virtual reality combine, the result is nothing short of remarkable. Similar to the aforementioned VR2GO and Socket HMD, the Altergaze is a 3D printable virtual reality machine designed to work with smartphones.

While it may not rival the Oculus Rift in terms of technical prowess, the Altergaze has a few tricks up its sleeve.

The team behind the Altergaze are allowing for their work to remain open-source, allowing for any owner of a 3D printer to become an official seller. This idea is helping to revolutionize the way products are being sold – resulting in more efficient channels of distribution, lower costs for the company and better products for the consumers.

Furthermore, it reduces a company’s carbon footprint, resulting in a greener environment for our future.

The Altergaze would, similar to other virtual reality products, have big implications for mobile gaming - allowing users to immerse themselves in a virtual world. Other possibilities would include virtual experiences at museums, music events and much more.

Currently, the Altergaze’s kickstarter campaign - while failing to reach the unprecedented heights set by the Oculus rift – has exceeded its $25,000 target. Altergaze are offering users 3 separate designs to choose from, 26 different colours for the plastic structure, 8 colours for the eyepiece and more than 20 smartphone bracket sizes.

3D Doodler

Moving along the branches of the technology tree, we present to you the world’s first 3D pen, the ‘3D Doodler’!

Created by WobbleWorks, this unique product gives users the freedom of 3D printing without the need for technical expertise. So long as you can draw, and have a power source available, then you’re free to create objects in any shape you like!

It’s basically a mini-printer - as the plastic heats up, it’s pushed through the tip of the lightweight pen, quickly cooling down to form ABS or PLA plastic structures.

3D Doodler also comes equipped with its very own stencils, helping you to unleash your imagination until you begin creating your own masterpieces. The online 3DDoodler community is growing fast, with plenty of solid advice for beginners and free stencils available.

This promising addition to the 3D printing world can easily become a powerful educational tool, and according to their website, WobbleWorks are already in contact with several educational distributors.

Although this technology produces 3D printable items, it’s still miles away from the complex builds traditional FDM (fused deposition modelling) printers can produce. 

Traditional 3D printers generally take hours to create a model, however, we can’t help but ask ourselves, would we spend hours on end holding a 3D pen?

Available for approximately £100 from the3doodler.com, it’s far cheaper than traditional printers, at the cost of severely reduced accuracy and extended man hours. 

Frequently Asked Questions

FAQ

What materials do you use?

We use multiple materials including, but not limited to: ABS, Rubber (Ninja Flex), Nylon, HIPS (High Impact Polysterene), T-glase (premium transparent material) and biodegradable PLA.

Feel free to contact us if you would like to print in a material not mentioned above.

Do you have any materials with special properties?

Yes, we have multiple, such as translucent, glow in the dark and UV reactive filaments. We can also offer different materials upon request, including LayBrick, LayWood, conductive filament and HIPS.

What type of 3D Printers do you use?

All our printers use FDM (fusion deposition modelling) technology. This means that models are built layer by layer - melting layers of molten plastic on top of each other, eventually resulting in a 3D model.

How long will it take to print my model?

The time it takes to print a model depends on its’ complexity and resolution. Therefore, time varies from build to build, and ranges from ten minutes to three days.

How big can my model be?

The model can be as big as you like. However, the maximum build volume of a single item is 23 x 22.5 x 20.5 cm, once a piece goes above this size, it will have to be built in separate pieces, and later adjoined to make them whole.

What resolutions are available?

Our machines are capable of printing anywhere from 300 microns down to 20 microns. Our quick print settings are:

Low - 300 mircrons
Medium - 200 microns

High - 100 microns

Ultra - 20 microns   

What colours can I print in?

Malta 3D Printing offers a wide range of colours, including: gloss, matt, transparent, UV reactive and glow in the dark variants. 

We also offer a spray paint service should there be a special colour scheme or detail you want to apply to your model.

How much will my model cost?

Costs are based on the time it takes to complete a model. Unlike other companies which charge by cubic centimeter, we charge based off the build time, ultimately resulting in a cheaper cost for our customers.

The final price will be agreed before the item is sent to print, which will include all printing material and labor (sanding, adjoining, spray work, chemical treatments etc.) costs.

We also offer a price match guarantee on all items!

What’s a ‘price match guarantee’?

A price match guarantee means that if you find another vendor offering a product at a lower price, then we will match or beat that price.

 All you have to do is send us an email at jugglingactindustries@gmail.com with proof of the product or service being cheaper, this must include full final price with tax and shipping (if included). We recommend taking screenshots.

Are you really the cheapest 3D printing company in Malta?

We strive to keep our running costs down, and pass the savings onto the customer.

Once I order my product, how do I get it?

There are 3 ways that you may acquire your product. We can mail it to you, deliver locally or you can pick it up in store at our offices in Birkirkara, Malta.

How can I customize a product to my liking?

If you wish to further customize your model, we will put you in contact with one of our technicians, who  allowing you to tell them exactly what you want done to the model.

Do you ship internationally?

Yes, Malta 3D Printing will gladly ship worldwide. 

What file formats do you accept?

We accept .STL files and .OBJ files. However, in some cases we can accept program specific files such as .AMF for Cura.  

Is it true that you offer step-by-step customer support?

Yes, once you make contact with us, we will be happy to provide you with easy to understand, detailed information on every step of the process.

Do you have any special offers?

Besides our price match guarantee, we also offer student discounts as well as regular competitions on our Facebook page. Keep an eye out for us on social media!

When can we contact you?

We are available 24/7!

How can we contact you?

Email: jugglingactindustries@gmail.com

Facebook: Malta 3D Printing

3D Printing Hubs: http://www.3dhubs.com/rabat/hubs/malta-3d-printing

Telephone: (+356)27031403

How to Place an Order

We process orders via Facebook, email, and at our main office in Birkirkara, Malta. There are two ways to place an order:

1) Quick Print: 

• Send the file (.stl, .obj, .thing) via Facebook or email (jugglinactindustries@gmail.com) 
• Receive a quote upon order confirmation
• Collect it at our main office or in the mail
  
                                                                           OR

2) Customized Print:

• Send the file (.stl, .obj, or .thing) via Facebook or email (jugglingactindustries@gmail.com), with selected customization options specified (see below)
• Receive a quote upon order confirmation
• Collect it at our main office or in the mail

The customization options possible include:

+Material
+Resolution
+Finish
+Paint
+Printer Speed Settings
+Software Options (slicer)
+Pictures of key stages of the print
+Video of the print
+Shipping

Note: Price will be calculated depending on customization options selected. Build time varies depending on print complexity. Customers will be kept well informed at all times!

 

Expect this blog to be a hub of exciting news and events surrounding Malta 3D Printing and the industry. Feel free to contact us to learn more about us and our services!

Facebook: http://on.fb.me/1nEZWRb

Phone: +00356 2703 1403

Thingiverse (Free 3D file library reference): http://www.thingiverse.com/

Our Guide to Overcoming 3D Printing Problems

Cracking 

Cracking is categorized by a print developing a split in between layers. It is generally caused by some parts of a print cooling faster than others.

To prevent this from happening, we ensure that our build area is kept at a stable temperature, free of excess wind currents. 

Warping

Characterized by lower levels of the print lifting away from the build plate, warping occurs when the bottom of a print cools unevenly to the top, a common affliction to 3D printers.  

To tackle this issue, we use heated build plates on all of our machines, and activate them on every print. We use different temperatures for different materials, to guarantee that regardless of the selected material, the base stays flat.

Curling

Curling is like warping, except this generally affects the top layers of a print. The edges of a print become distorted, potentially resulting in sharp edges and weakening the print’s structure.

Often a side-effect of excess heat, we make sure that we print at the optimum temperature to completely factor out this issue. 

Build Plate Detachments

This occurs when the base layers of the print detach from the build plate, resulting in a failed print.

This can happen for multiple reasons, for example, the extruder hitting the print, knocking it off the build plate. Or, heavy warping can result in detachment as well as excessive curling.

We have multiple methods of adhesion for each different material that we use. This enables the print to stick to the build plate, meaning that detachment becomes nearly impossible.

Power Outages

We use UPS (uninterruptible power supply) to compensate for any power outages.

Normally, a blackout would result in the loss of a print, resulting in the process having to be restarted. Thanks to our UPS, you can rest assured that your print will be safe and sound.

Air Printing

Air printing occurs when a hot end continues plotting its programmed route, yet there is no material being extruded. This results in a failed print. Often, the last few layers would also be under- extruded, and renders the print irretrievable.

However, if under-extrusion did not happen, one may set the printer to carry on from a layer above the last successfully extruded line.

A typical cause of air printing is when heat travels up the filament and melts it. This results in the filament drive gear pushing on melted material, and clogging the gears. To tackle this, our filament drive gears are located at the back of our machines, making this problem extremely rare. 

Some machines are better at printing certain materials than others. This is commonly attributed to the hot end nozzle design. Some printers have larger nozzles, resulting in more heat being produced, affecting surrounding instruments. In some cases this can burn the filament, clogging the hot end. This would generally require deconstruction and a thorough cleaning.

Malta 3D Printing also uses different machine for each type of material. This, combined with the aforementioned methods successfully eliminates any nozzle design and drive gear issues.

Wavy Surfaces (uneven finish)

This is when a product has wavy, uneven lines on its surface. This is generally attributed to the XY belt not being tight enough.

We regularly service our machines to prevent this.   

Bubbles/notches on Final Print

Bubbles occur when air pockets get trapped in the print. This is caused by the temperature of the extruder being too high, resulting in the hot end boiling the plastic. 

As it cools, the air bubbles get trapped in the print, meaning it becomes a permanent fixture in the final model.

To cater for this, we always use the appropriate printing temperature for all materials and colours (if you have read thus far you will know that correct temperatures also prevent many others problems).
 

Under Extrusion

When this occurs the lines of filament that make up the print may have gaps in them, or may suffer uneven extrusion.

Under extrusion has various causes, such as using weak, humid or fragmented material, as well as filament with excess air bubbles. Furthermore, undesirable temperatures can also increase the likelihood of under extrusion.

Malta 3D Printing uses premium filament, purchased from reputable brands including: MakerBot, taulman 3D, and NinjaFlex. This material has been purchased due to its special properties and reliability, as well as the filament guaranteeing against the issues mentioned above.

Additionally, all our material is stored in a cool and dry environment, negating all humidity concerns.

Burn Marks

Burn marks appear as brown or black marks on or within the print. Burn marks are a result of the hot end temperature being way too high.

Alternatively, curling may occur, causing a part of the print to be repeatedly hit by the hot end nozzle, initially melting the surrounding areas, eventually burning the print.

As previously mentioned, we always print at optimum temperatures and have measures in place to prevent curling. Therefore, we do not encounter this problem.

Discolouration

Print discolouration can appear when two or more colours are present towards the base of a model.

This occurs when some of the previous filament is still left over when changing printing materials. This leads to discolouration and colour streaking.

To counter this, we purge our machines upon each material change, to ensure the previous filament has been completely removed.

Cuts, Scrapes and Bruises (to technician/staff)

Since the build plate and the extruder require heat to function, as well as numerous moving parts (the gantry, the X and Y axis belts, the build plate, the filament drive gears etc.) our technicians are often in the line of fire, frequently falling prey to the epic dangers that manifest themselves in the dark nooks and crannies of 3D printing. 

All jokes aside, our technicians have vast experience in multiple areas of design and manufacturing, and continue to produce top quality products  for growing customer base.