3D metal printing is
becoming a driving force
in the production of
many of today’s medical
devices, says GF Machining
Solutions
Integrated approach
GF Machining Solutions offers a complete AM solution for medical device manufacturers. The company
says that it sees it as an integrated technology solution, as it explains here
Metal additive manufacturing (AM)
— also known as metal AM or 3D
metal printing — is becoming a
driving force in the production of many of
today’s medical devices. In fact, orthopaedic
implants with porous surfaces and lattice
structures mimicking the behaviour of normal
bone have led to signi cant improvements in
patient outcomes, and implants with these
features simply cannot be made without AM.
Moreover, it is not just implants that have
new designs; surgical tools and instruments
also bene t from simpli ed manufacturing
processes, weight savings and ergonomic
features that can only be made with AM.
Not surprisingly, then, it is estimated that
as much as 10% of all orthopaedic implants
being introduced have at least one
component made by AM.
However, starting a new department for
AM carries many challenges. As metal AM
grows in importance, original equipment
manufacturers (OEMs) and subcontractors of
all sizes are investigating how to best
integrate this technology in order to better
meet their customers’ needs.
With a complete ‘end-to-end’ solution that
brings customers best-in-class quality,
together with lowest running costs,
GF Machining Solutions ( www.is.gd/zuredi )
and 3D Systems ( www.is.gd/uzehip ) recently
launched the DMP Flex 350 to help ensure
success when adopting this new technology.
There are various technologies for printing
metals, but the dominant approach today
creates solid material through the targeted
melting of very ne metal powder. DMP
Factory and Flex systems from GF Machining
Solutions and 3D Systems use a laser-based
process (selective laser melting) that can
produce high quality surface nishes and
small features (down to 0.1 mm).
A key consideration when investigating
metal AM technologies is the range of
materials the respective systems can print,
as well as the ability and speed to change —
or not change — materials if necessary.
For example, surgical instruments are
most often made of stainless steel, while
surgical implants usually require titanium.
If the manufacturing objective or priority is to
fully load a 3D printer with different types of
jobs, a exible system allowing ef cient
material changes will be your natural choice.
The DMP Flex 350 has been engineered to
allow a user to change the metal being
printed in only a few hours. On the other
hand, the DMP Factory series is designed for
MEDICAL SECTOR A COMPLETE SOLUTION
use with a single metal. With the DMP Factory
and a DMP Flex versions of the system,
manufacturers can invest in the technology
that is right for them.
When it comes to 3D metal printing,
oxygen is the enemy. When metals such as
titanium are in its presence, they degrade
through oxygen uptake. GF Machining
Solutions’ system’s unique design makes
use of a sealed build chamber to create the
optimal printing environment by evacuating all
air from the chamber and replacing it with
argon. This cycle is repeated three times
before the build begins, removing both oxygen
and any trace of humidity from both the
chamber and the powder reservoir.
With this unique approach, the oxygen
level present during operations is around
25 ppm, compared to 300 to 700 ppm of
oxygen in other systems’ build chambers
(which most often have a continuous ow of
argon entering the chamber). The results with
the GF Machining Solutions system mean
better and more consistent product quality,
build after build, and lower operating costs
through both reduced argon consumption and
a longer useful life for the metal powder.
Even with its many advantages, the DMP
Flex 350 is just one part of the metal AM
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | November 2020 23
/zuredi
/uzehip
/www.machinery.co.uk