Individual bone implants from the rapid prototyping bakery

Individual bone implants whose structure resembles that of the natural bone can now be produced quite easily. First, a simulation program calculates the bone’s internal structure and porosity, then a rapid prototyping machine “bakes” the implant from metal powder.

Researchers at the Fraunhofer Institute for Manufacturing Technology and Applied Materials Research have developed the simulation program that calculates the internal structure and density distribution of the bone material. From this, the scientists were able to derive the material structure for other components.

The engineers can meanwhile produce complex components with the aid of rapid prototyping technology. “It’s like baking a cake,” says Andreas Burblies, spokesman for the Fraunhofer Numerical Simulation of Products, Processes Alliance. “The end product is an open-pored element,” explains Burblies. “Each point possesses exactly the right density and thus also a certain stability.”

The method allows the engineers to produce particularly lightweight components – customized for each application – that are also extremely robust. These can be individual bone implants, but also aircraft, automobile and machine parts. In the meantime, the researchers have further enhanced the process to the point where they can actually change the internal structure of the parts after production by means of precision drilling.

Fraunhofer Institute for Manufacturing Technology and Applied Materials Research IFAM
Andreas Burblies
andreas.burblies@ifam.fraunhofer.de
www.ifam.fraunhofer.de