The Netherlands Archives - Perfect 3D Printing Filament

FELIXprinters Adds Two High-Temperature 3D Printing Systems to Industrial Portfolio

Family-run industrial 3D printing solutions provider FELIXprinters, headquartered in IJsselstein, the Netherlands since 2010, works to create what it calls “holistic AM solutions” for its customers , developing “tailor-made” platforms for specific applications, rather than simply selling off-the-shelf solutions. A year ago, soon after the introduction of its Pro 3, the Dutch company added the FELIX PRO L and XL 3D printers to its portfolio, which scaled its precision technology up to more large-scale build volumes. The robust systems reliably provide larger parts, without giving up the quality that FELIXprinters is known for, and can easily fit into workshop spaces.

Not long ago, the company launched its first 3D bioprinting system, and now, even amidst the many challenges brought on by the global COVID-19 crisis, has been busy at work. This week, FELIXprinters announced the addition of a new range made of two high-temperature 3D printers.

“Like all businesses as we moved through the first quarter of 2020, we have had to adapt and adjust the way that we work. As soon as it was obvious that the coronavirus pandemic was going to severely disrupt the usual way of working, we made some far reaching and strategic moves to ensure the continuity of production or our 3D printers, and also our relationships with our customers. First and foremost, we had to ensure that our FELIX team could operate in a way that they were comfortable with and which guaranteed their safety. So from very early on, we ensured that they had masks, had access to all the sanitiser and hygiene measures that they needed, and that we put in place protocols that meant everyone in the factory could work while maintaining social distancing requirements,” said Wilgo Feliksdal, Co-Founder of FELIXprinters.

“Once this had been arranged, and with the continued demand for our industrial range of 3D printers and our newly introduced BIOprinter still high, it became clear to us that we were in a position to continue our 2020 plans relatively uninterrupted. Earlier in the year we had received a tender from a large multinational client looking at the possibility that we could produce a series of high temperature 3D printers, and we have now geared up to produce these in large batches through Q2 and Q3.”

While we don’t yet know the name of these new high-temperature AM systems, we do know that they feature customizable print heads, a 600 x 600 x 600 mm build volume, and a secure enclosure with a HEPA filter.

High-temperature 3D printing makes it possible to use stronger, advanced, and functional engineering-grade materials, such as PEKK, PEI, and polyamides, which then allows manufacturers to fabricate parts that are needed for rapid prototyping purposes, and practical end use applications, in the aerospace, engineering, and architecture industries. As the new FELIXprinters high-temperature systems can print anywhere from 100-400°C, I’d say they fit the bill.

“There is no doubt that we are in unprecedented times, and we like many companies operating in the 3D printing space are having to adapt our ways of working as we begin to defeat the coronavirus, and we are delighted that despite everything we have successfully developed our high temperature solutions,” said Guillaume Feliksdal, FELIXprinters Co-Founder. “In many ways, the 3D printing sector is unique in that it is likely to see an upswing in attention as globally, companies begin to reassess and localise their supply chains. At FELIXprinters, the continued demand for our industrial 3D printers, the enormous interest in our BIOprinter, and the recent developments we have made in term of high temperature additive manufacturing show the vibrancy of the niche, and also demonstrate the resilience of industry as we all drive on and innovate, even in these difficult times. I feel we have the edge in many areas due to an exceptional, dedicated, and passionate team, and I would like to thank each and every one of them for their hard work and talents.”

While the new high-temperature 3D printers aren’t available just yet, FELIXprinters has said that they are mere weeks away from commercial use. So we’ll have to stay tuned for more information.

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Addmio Kickstarter Campaign for ‘3D Printing for Entrepreneurs’ Online Course

As the 3D printing industry continues to grow faster, more accessible, and more affordable, it’s important that businesses continue learning about the many benefits it can offer them. We’ve seen classes on 3D printing for entrepreneurs before, but the application-focused, efficient course that the Netherlands-based e-learning company Addmio is soon launching will be easier to access because it’s on an online educational platform.

Robin Huizing, a former 3D printing engineer for Shapeways and additive manufacturing designer for Additive Industries, lives in the Dutch city of Eindhoven and ran his own design studio for nearly 12 years, before deciding to launch the Addmio platform.

Addm.io founder Robin Huizing

“I started Addmio to help the 3D printing industry flourish and to educate all of the entrepreneurs and creatives worldwide,” Huizing said. “I want to help them to create better products and businesses with 3D printing.”

Huizing trained and taught hundreds of people about 3D printing in his former jobs, giving lectures, master classes, presentations, and workshops to many large companies. But he realized that sharing knowledge in these ways was “not scalable,” and not making enough of a difference for entrepreneurs interested in learning more about AM. That’s why he decided to found Addmio.

Once things got started, he began researching existing courses and training programs, and found that the high-quality ones were costly, time-consuming, and only on-location. Classes that were more affordable provided, at best, general information about the technology, and did not offer attendees a quality experience. So Huizing determined that to really make a difference, Addmio should offer less expensive, higher quality courses that were focused on specific 3D printing applications.

“Because we can make our courses available for thousands of people at the same time, we can keep the costs very low. The value for money we’re able to offer is unparalleled,” he wrote in a press release.

The first course Addmio is developing is called 3D Printing for Entrepreneurs, which features three unique aspects:

extremely efficient: it condenses five years of work in the 3D printing industry into just three days
application-focused: the course provides many examples in showing users how to choose the right application
100% online: it is a mobile-first, web-based course so learning can take place anywhere, at any time

“We’re developing the course “3D Printing for Entrepreneurs” for creatives and startups, to learn about all the opportunities 3D printing has to offer for your startup or side business. We want to make sure that you have everything you need to learn and start your business, all from home,” the website states.

Huizing will be the main instructor, and the course will provide on-demand, video-based lessons relying on knowledge from industry experts. In-course assessments are included, and at the end of the class, participants will receive a digital certificate. In addition to the course, Addmio will also be offering 3D printable files and a support program for 3D printing startups that includes a tailored advisory report with advice and tips to help startups get on their feet.

Rather than working with investors or banks to get the Addmio course up and running, the company is turning to crowdfunding “because it seamlessly fits our philosophy.” Its Kickstarter campaign launched this morning, so creators and makers from around the world can contribute. In return, the company will help startups create successful 3D printing businesses.

“This is why we came up with an online platform. This is the only medium that is ultimately scalable. Our courses can help people 24 hours a day, in 100 countries at the same time,” the campaign site states.

“All you need to follow our course is a phone, tablet, or computer with an internet connection. That’s it.”

The campaign goal is just €2,500, and there are multiple reward levels – for example, an early bird pledge of €82 means you can get the complete 3D Printing for Entrepreneurs online course for a discount of 40%, while a €137 pledge gets you the early bird course and STL files of objects used in the course.

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Successes In 3D Printing Spinal Implants in Two Complex Cases

In the recently published ‘Challenges in the design and regulatory approval of 3D printed surgical implants: a two-case series,’ authors Koen Willemsen, Razmara Nizak, Herke Jan Noordmans, René M Castelein, Harrie Weinans, and Moyo C Kruyt explore the use of 3D printed implants for treatment of spinal conditions, studying two different cases.

Both patients exhibited ‘semi-urgent’ cases of spinal instability as they were admitted to the researchers’ hospital in the Netherlands:

Case One – severe kyphotic deformity of the thoracic spine due to neurofibromatosis, causing incomplete paralysis, with a metallic strut used to provide anterior support
Case Two – progressive paralysis caused by cervicothoracic dissociation due to vanishing bone disease, with an implant spanning the anterior spine inserted

Both cases were considered complex, and traditional techniques ineffective. To overcome previous obstacles, the researchers 3D printed titanium implants created from their CT scans. The customized medical devices were fabricated with direct metal printing and then tested for strength, as well as biocompatibility. The researchers point out that previously, surgeons had been concerns about using 3D printed implants because of restrictive legislative regulations in the Netherlands, but throughout this study, the effectiveness of such patient-specific treatment with successful outcomes was emphasized.

“An exemption from the usual approval procedure for the use of personalized implants can be obtained in an emergency or exceptional-use situation, when specific safety requirements are met. We believe that thorough and efficient interactions between medical engineers and physicians to establish well-designed frameworks to navigate the logistical and regulatory aspects of personalized implant development are necessary,” stated the researchers. “These frame-works can be locally administered and managed to obtain legal clearance for personalized implants in an optimal manner; only then can the possibilities be effectively exploited and the expected increase in personalized solutions accommodated.”

During the study they describe workflow and framework for 3D printing for complex surgeries for the patients, exhibiting ‘severe destruction’ of the spine. Because of the complexities of the spinal conditions, there simply were no standard devices or surgeries available, but the researchers explain that without implants of some sort, the patients were in danger of developing paraplegia. In the meantime, their spines were being protected with the external orthoses.

Case one refers to a 16-year-old boy who had previously been treated for severe dystrophic scoliosis; fusion failed over time, however, and his situation was becoming more dire.

“We concluded that a strong and solid metallic strut would be needed at the anterior side to assure reliable long-term support. Such a prosthesis had to be fixed and would ultimately need to integrate into the proximal and distal viable vertebral bone without interfering with vital structures such as the heart, lungs, and bronchi. The shape of the prothesis had to be customized to ensure a perfect fit,” stated the researchers.

The medical device was allowed for use due to the exceptional details of the case.

(A) The first step in the design process: a prototype that follows the mechanical axis near the spine, attaching to the last mechanically stable vertebrae in the cervical spine (C4–C5) and bridging the unstable part (C6–T11) to the first mechanically stable vertebra distal of the defect (T12). (B) Restructured prototype with the addition of screw holes and their trajectories. (C) Final implant design (rendered picture). (D) Close-up view of the porous mesh structure to allow bone ingrowth, with distal screw holes

Two proximal and distal screw holes were included in the implant for fixation, and in-silico analysis was performed. The implant ‘easily sustained’ axial stress of 500 N, and a biomechanical compression test showed ten times more stiffness and strength than a traditional 5.5 mm titanium rod. The implants were 3D printed using medical grade titanium on a DMP320 3D printer, and implanted six months after the emergency stabilization surgery—which was ‘uneventful and went as planned.’ The surgical procedure took only 150 minutes, and there were no complications. The patient recovered well, went home in a week, and did well, despite a fatigue fracture that had to be repaired in one of the rods.

The second patient was a 68-year-old female who had already received several surgeries, with the vanishing bone disease a condition of ‘unknown cause characterized by the destruction and absorption of bone.’ Due to a trauma, the posterior fixation in place failed and caused her spine to collapse—resulting in neurological problems.

“After approval from the surgical team, the personalized implant and one oversized version (with an additional 3 mm in height) were printed in titanium following the same production method as that for case 1,” stated the researchers.

Post-implantation imaging

The implant was inserted six weeks after the stabilization surgery, with no complications. Surgery only took 120 minutes, and the patient did well afterward. After six months, the patient was walking normally again.

“When the primary concern is the health of the patient, the surgeon can take responsibility for decisions that might deviate from the typical regulations, as long as they verify the safety of the treatment approach by providing argumentation and the rationale in the technical file for the implant,” concluded the researchers, who are hopeful that this study will accelerate the use of personalized implants.

3D printed implants are a fascinating subject today, not only because there are so many different types, but because of the ability they have to change a patient’s quality of life, from cochlear implants to titanium implants and even mandibular grafts. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

[Source / Images: ‘Challenges in the design and regulatory approval of 3D printed surgical implants: a two-case series’]

The post Successes In 3D Printing Spinal Implants in Two Complex Cases appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

atum3D Installs Operator Station Software and DLP Station 5 3D Printer at Sirris Technology Collective

Digital light processing (DLP) specialist and open platform 3D manufacturing company atum3D, based in the Netherlands, introduced the latest version of its intuitive Operator Station print preparation software, complete with proprietary MAGS AI technology, at formnext 2018. The software makes it easy to duplicate parts, or fill available build volume, and comes with a slicing preview feature, while MAGS AI will automatically adjust a part’s orientation and generate the necessary supports, based on surface markings made by the user.

Now the company has announced its first onsite installation of the newly updated software solution. Sirris, a Belgian industrial collective center started by the technology industry for the technology industry, provides companies with a high-tech testing infrastructure and is also a partner organization in the Family of the Future project. The collective, which also has a DLP Station 5 3D printer from atum3D, will expand its current offering with the updated Operator Station solution.

“A barrier for printing parts are often the high costs related to the monopoly of or restrictions of material suppliers,” explained Maxime Legrand, Engineer Additive Manufacturing at Sirris. “With this equipment Sirris wants to support companies in the development and the production of their new AM applications at an affordable cost due to the higher flexibility in potential printing materials. This will enable new possibilities that couldn’t be met before. This atum3D setup allows us to demonstrate it’s now possible to quickly create high quality prototypes and end-products with a wide range of different material properties in a cost-efficient way, all with an investment around the € 25k mark.”

Sirris is made up of 150 tech experts, who work together to help around 1,300 companies a year achieve success in their innovation projects. By combining atum3D’s updated Operator Station with the open platform of the DLP Station 5, the collective and the companies it assists will benefit from easier print preparation.

“Operator Station guides you through the job preparation steps, from importing and supporting a part to selecting a resin and from duplicating or filling the build platform to slicing and exporting the job for DLP Station,” said Legrand. “It’s incredibly easy to use.”

The latest release of Operator Station, which uses an algorithm to consider not only the part’s geometry but also its resin properties, also includes a new object scaling functionality.

“We are thrilled to add DLP Station 5 with Operator Station to the state-of-the-art solutions offered by this Belgian innovation leader. Preparing for print has never been easier, with Operator Station’s intuitive touch-ready user interface and atum3D’s proprietary MAGS AI technology, which takes an entirely new approach to print job preparation,” said Guy Nyssen, channel manager at atum3D.

By pairing Operator Station software with the DLP Station 5, which features high accuracy, a free selection of build materials, and print speed up to 90 mm an hour, print preparation is a breeze, especially for new users like those at Sirris.

atum3D delivered the Operator Station to the Sirris Liège location, and installed both the hardware and the software there for the collective. In addition, the company also provided a user training session, which the new users at Sirris found to be “very self-explanatory.”

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[Images provided by atum3D]

Researchers Compare Human Cadavers and 3D Printed Anatomical Models to Determine Print Accuracy

3D pelvis model in Meshlab.

Surgeons often turn to innovative technology, like 3D printed anatomical models, to get a closer, more detailed look inside a patient’s body ahead of complex procedures. In particular, these models can help trauma surgeons determine the best approach to fixing complex fractures. But just how accurate are these 3D printed models when it comes to matching the look of human bone?

Accuracy is very important when it comes to the fitting of surgical guides and plates, as it’s difficult to characterize and analyze these fractures ahead of time, even with the help of CT scans. But a collaborative group of researchers from the Netherlands just completed a validation study to test the accuracy of 3D printed anatomical models for surgical planning purposes.

Their results were published in a paper, titled “Validation study of 3D-printed anatomical models using 2 PLA printers for preoperative planning in trauma surgery, a human cadaver study,” in the European Journal of Trauma and Emergency Surgery; co-authors are Lars Brouwers from Elisabeth-Tweesteden Hospital, Arno Teutelink with Bernhoven Hospital, and Fiek A. J. B. van Tilborg, Mariska A. C. de Jongh, Koen W. W. Lansink, and Mike Bemelman from Elisabeth-Tweesteden Hospital.

“Surgeons generally need years of practice to transform a two-dimensional (2D) image into a three-dimensional (3D) image in their mind in order to get a proper understanding of the fracture patterns. CT software however easily enables volume rendering of 2DCT into a 3D reconstruction,” the study’s introduction reads.

“3D printing has become increasingly utilized in the preoperative planning of clinical orthopaedics, trauma orthopaedics and other disciplines over the past decade [2]. 3D-printed models are readily accessible due to the wide availability of 3D printing techniques and 3D printers. 3D printing contributes to a better understanding of the surgical approach, reduction and fixation of fractures, especially in complex fractures such as acetabular fractures.

“However, it is unclear how a 3D-printed model relates to a human bone. To our knowledge, there is no literature that validates the accuracy of 3D-printed models in a preoperative planning strategy when applied to real human bones.”

The team dissected nine human cadavers to acquire three specimens each of a pelvis, hand, and foot, and inserted Titanium Kirschner (K-) wires in them to mark important anatomical landmarks. In order to convert CT scans in the DICOM file format to STL, the team used a Siemens Somatom Definition AS 64-slice CT to scan the specimens at a slice thickness of 0.6 mm, before moving on to the next stage of image post-processing.

3D model of a pelvis after CT scanning with all measurements between the five marker points performed on the Philips Intellispace Portal.

Phillips Intellispace Portal software was used to render the the DICOM data into 3D reconstructions, and then the data was digitally cleaned and saved as STL files, the landmarks of which were measured by two independent reviewers using open source Meshlab. The files were then imported and the G-code generated, and then the models were 3D printed, in a ratio of 1:1, on both an Ultimaker 3 and a Makerbot Replicator Z18 using PLA material.

Then, the independent observers measured the distances between the K-wires on the 3D printed models and the human cadaver specimens, in addition to Meshlab, 2DCT, and the 3D reconstructions. These distances were measured a second time one month later, with the exception of the specimens, as these had to be disposed of quickly. In addition to analyzing the observers’ data, the team also completed some calculations to provide an overview of the print process settings.

According to the study, “The least decrease in average distance in millimetres was seen in “the 3D printed pelvis 1”, − 0.3 and − 0.8% on respectively the Ultimaker and Makerbot when compared with cadaver Pelvis (1) The 3D model of “Hand 2” showed the most decrease, − 2.5 and − 3.2% on the Ultimaker and Makerbot when compared with cadaver hand (2) Most significant differences in measurements were found in the conversion from 3D file into a 3D print and between the cadaver and 3D-printed model from the Makerbot.”

Cadaver hand with titanium K-wire marker points next to its 3D printed model. The K-wires are visible on the 3D printed model.

The team concluded that 3D printing can be used to create accurate medical models that are “suitable” for pre-op planning; they also determined that the Ultimaker 3 was just a little more accurate than the Replicator Z18. The researchers recommend that any medical professionals who use 3D printed models for surgical planning first test out the accuracy of their own 3D printing processes.

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[Images: Brouwers et. al.]