The orthopedic implant industry plays a critical role in modern healthcare, providing solutions that replace or support damaged bones and joints. These implants, ranging from hip and knee replacements to spinal fixations, have traditionally been manufactured using conventional methods like machining and casting. However, with the introduction of additive manufacturing (AM), the production of orthopedic implants has experienced several improvements.
This article covers the benefits of additive manufacturing in the orthopedic implant industry, market potential, and how Freemelt’s e–MELT® machine is enabling serial production of titanium orthopedic implants.
Market potential and industry growth
The global orthopedic implant market is experiencing strong growth, driven by factors such as advances in medical technology, the prevalence of chronic diseases like Osteoarthritis (A condition that involves wear and tear of cartilage in the joints, leading to pain, stiffness, and reduced mobility), as well as an aging population. A growing number of individuals, including middle-aged adults and retirees, are today receiving implants as they seek to maintain an active lifestyle well into later years. Additionally, the development of implants with fewer complications has led to younger people opting for them, increasing the overall demand. As a result, implants are becoming more common, as they are now used for a greater number of years due to their extended lifespan.
In 2023, the market returned to pre-pandemic growth rates, showing a growing demand for various orthopedic devices. By 2032, the orthopedic implant market is expected to reach $86 billion, growing at a compound annual growth rate (CAGR) of 5%1. Meanwhile, the 3D printed orthopedic implant market is projected to grow even faster, with an expected CAGR of 16%, reaching $7 billion by the same year2. Several global healthcare companies are at the forefront of this expansion, including, Zimmer Biometh, Stryker, and DePuy Synthes (a Johnson & Johnson company), where Stryker alone has manufactured over 2 million 3D printed implants since 20133. These industry leaders are continually advancing their offerings, and manufacturing techniques such as additive manufacturing to address the evolving demands of the healthcare sector.
The benefits of additive manufacturing for orthopedic implants
Additive manufacturing is transforming the orthopedic implant industry, enabling implants with intricate geometries and porous structures, leading to lighter implants with improved bone ingrowth, superior fit and function, less complications, and faster recovery times. Within AM the E-PBF (Electron Beam Powder Bed Fusion) technology is extra efficient. The E-PBF technology fulfills all applicable material standards and improves production efficiency, by providing higher melting efficiency, minimizing waste, and reducing internal stresses. E-PBF operates under a vacuum environment, which preserves both the integrity of the parts and the unused powder, resulting in a lower powder scrap rate. The E-PBF process employs higher power levels for more efficient melting and operates at elevated temperatures. This approach reduces residual stresses, allowing for efficient stacking of parts and optimal use of build space. Additionally, the E-PBF process produces parts in their net shape with the desired properties, eliminating the need for further heat treatment. Titanium, especially the Ti-6Al-4V alloy, is a key material for orthopedic implants due to its exceptional strength-to-weight ratio, biocompatibility, corrosion resistance, and fatigue resistance.
Additive manufacturing has the potential to revolutionize orthopedic implant production, creating new opportunities for innovation and efficiency.
Image 1. Titanium porous structure designed to enable bone ingrowth
Printed in a Freemelt machine
Freemelt enables serial production of orthopedic implants with e–MELT®-iM
Freemelt’s e–MELT®-iM machine is set to revolutionize the orthopedic implant industry with its advanced capabilities tailored for serial production. Unlike conventional manufacturing and competing additive manufacturing technologies, the e–MELT®-iM excels in producing complex, high-quality implants at scale. Its modular design and quick turnaround capabilities allow manufacturers to efficiently scale up production while maintaining exceptional precision and accuracy.
The e–MELT®-iM stands out by optimizing material usage and streamlining the production process, ensuring that cost per part remains competitive or even lower than traditional methods. As the orthopedic implant industry experiences significant growth, Freemelt’s technology empowers implant OEMs (Original Equipment Manufacturers) to meet rising demand with faster production times, enhanced cost-efficiency, and unparalleled quality.
Key features of Freemelt’s e–MELT®-iM
1. Modular and independent build modules
With four melt stations and interchangeable build modules, the e–MELT®-iM enables continuous, high-efficiency production. This is ideal for scaling up operations and maximizing output while keeping operational costs low.
2. Efficient turnaround
A separate turnaround station ensures that the preparation and removal of builds can be done ergonomically and without blocking the melt station. This minimizes downtime, thus enhancing overall productivity.
3. High beam power
The e–MELT®-iM features a high-power electron beam that allows for faster melting and quicker build rates, crucial for industrial serial production.
4. Compact build volume with active cooling
e–MELT®-iM’s compact build chamber, combined with active cooling, substantially increases productivity. These unique features make e–MELT®-iM optimal for manufacturing of orthopedic implants.
5. Spot melting, Pixelmelt®
Freemelt’s spot melting technology enables unparalleled flexibility in the management of the melting and as a result the heat management process. Pixelmelt® reduces the need for support which reduces the amount of postprocessing.
6. Stacking capabilities
e–MELT®-iM supports the stacking of parts in the build chamber, optimizing space utilization. The sintered nature of the powder bed acts as a support structure, minimizing the need for additional printed supports, which often increases material waste and processing time.
Image 2. Stacked acetabular hip cups Image 3. e–MELT®-iM
Printed in a Freemelt machine
Conclusion
As the demand for orthopedic implants increases, driven by aging populations and advancements in medical treatments, the industry is gradually shifting toward more innovative manufacturing methods. Freemelt’s e–MELT®-iM, with its advanced E-PBF technology, supports this transition by offering improved efficiency and cost-effectiveness, setting a new standard for serial production of orthopedic implants.
Sources
1. Orthopedic Implants Market Share, Size, Growth 2032 | MRFR (marketresearchfuture.com)
2. 3D Printed Orthopedic Implants Market Size [2032] (businessresearchinsights.com)
3. Stryker 3D printed over 2 million Tritanium implants since 2013 (voxelmatters.com)
Additional reading
Rediscovering titanium: New ways to make old things
eMELT-iM: The Industrial 3D printer for serial production
eMELT-iD: The 3D printer for your development needs
