‘3D printing empowers international corporates and local businesses to unleash creativity’

Streamlining healthcare costs and increasing healthcare access are two major challenges that India faces. Rajiv Bajaj, GM India, Stratasys India explains how innovative technologies such as 3D printing is the solution to this problem, in an interaction with Raelene Kambli Excerpts….

How can 3D printing enhance surgical and treatment options for patients?

3D printing or additive manufacturing is an innovative technology that is being adopted by companies all over the world. It is used in conceptualising new ideas and testing for product functionalities, as well as for direct manufacturing of tools and end-use parts since its invention almost 30 years ago. This applies to the medical arena too as medical device manufacturers can benefit from streamlined product development cycle of surgical tools, as well as higher flexibility in innovations without design and production constraints; subsequently producing a wider variety of and more customised medical devices that cater to the needs of different patients.

In addition, application of 3D printing in pre-surgical assessments result in enhanced surgical preparedness, reduced complications and decreased operating time for surgeons and patients. For example, five-year-old Mia Gonzalez suffered from a rare heart malformation called double aortic arch, a condition in which a vascular ring wraps around either the trachea or esophagus, restricting airflow. This required multi-faceted surgical procedures. 3D printed anatomical models (generated from CT or MRI scans) enabled surgical teams to scrutinise the actual condition of a patient and visualise the surgical solution on the printed model, such that the best course of action could be planned and executed seamlessly for the patient’s speedy full recovery.

What are the opportunities that 3D printing technology offers for products such as prosthetics and implants?

3D printing is changing the way prosthetics are designed and produced. Its capabilities offer a faster, more streamlined method to medical product manufacturers for developing clinical trial-ready devices and implants in-house and validating form, fit and functions to manufacturability. It also enables customisation in prosthetic and implant designs with minimised cost and time, benefitting both manufacturers as well as patients. For example, engineering students of University of Central Florida (UCF) developed a customised robotic arm for six-year-old Alex Pring using a Stratasys Dimension Elite 3D Printer.

3D printing also makes it possible for medical and dental implants to replace missing teeth with pinpoint accuracy and minimum discomfort during surgical processes. Many laboratory professionals have discovered that 3D printing of dental models is faster, more economical, predictable and accurate. The power of 3D printing lies in such instances, where users can 3D print prosthetics or implants in a matter of days instead of weeks or even longer.

Is it cost effective and how?

3D printing can help medical solutions manufacturers reduce production cost dramatically in comparison to traditional medical solutions. One brilliant example was the UCF using the Dimension 3D printer and engineering-grade thermoplastic, ABSplus, to prototype and produce end-use prosthetic arm for Alex. Traditional medical solutions would cost up to $40,000 to create one prosthetic arm and might not be able to adapt to the size of a child due to design constraints. Instead, the total cost of the materials and printing cost of Alex’s prosthetic arm cost only $350, and the robotic arm could easily be updated as the child grew by printing a new hand for approximately $20, or a new forearm for $40.

How do you see this technology scaling up?

Started over 25 years ago, 3D printing can be applied to produce parts across a wide range of industries and applications. From fully-functional medical prototypes such as knee braces for improved design efficiencies to manufacturing in-flight aerospace parts, right through to high-strength automotive components that can withstand the heat and endurance of high impact functional tests, the technology and its material has advanced rapidly, finding usage across various design and manufacturing stages. The technology is not restricted to a particular industry, country and continent and hence, its application is diverse. Combined with the increase in demand for efficient manufacturing, we are convinced of the long-term growth opportunity for 3D printing in the global environment as well as in Asia.

Has India taken to the technology? What are its benefits in the Indian context?

In comparison to the global markets, India is relatively young in adopting 3D printing technology, but the market is continuously picking up speed in not just 3D printing adoption, but also education and awareness, as different sectors see the benefit that 3D printing brings to their world (e.g. to better understand abstract ideas, to create things that are impossible to create previously due to many production constraints). We see Indian hospitals using 3D printers, not just to produce anatomical models, but also various implants (skulls, jaws, to name a few) for advanced examination. Indian manufacturers are using 3D printers to produce end-use parts directly, schools are using it to prepare students for their future career where 3D printing shall play an integral part in the design and engineering spectrum. As one of the industry leaders, we are also working towards increased awareness, so that in addition to operating the 3D printers, customers can be empowered to innovate and maximise their investment and businesses in parallel.

Explain the technical convergence that has made 3D-printed personalised medical devices possible.

One of the most recognised values of 3D printing lies in its ability to create repeatable yet customisable products without the need of mould, patterns or casting tools – which are often the most expensive elements during the manufacturing process. Instead of extracting from blocks of materials, users send CAD designs to the software of the 3D printer, which converts the digital data into compatible format before adding layers over layers of materials to realise the designs according to pre-set coordinates.

In the US, people are using this technology at home to create missing hands, limbs, legs etc. Can this be replicated in India?

At the moment, Stratasys focuses on the professional market where 3D printing offers solutions to companies and organisations to overcome their business challenges, including medical device research and development, surgical tools design as well as customised low-volume manufacturing of certain medical solutions such as prosthetics. Having said that, sky is the limit when it comes to innovation; and Stratasys is dedicated to serving different needs of our customers through continuous investment in 3D printing technology to push the boundaries of the industry.

Tell us about Stratasys’ market share in this segment; worldwide and in India?

Asia Pacific & Japan (APJ) has contributed significantly in recently years. The medical segment has always been a key vertical for us and we offer a wide range of applications such as realistic anatomical models, customisable surgical tools, medical devices and components etc. There are few reports gauging the progress of the medical segment, but it has been one of the key verticals at Stratasys, alongside automotive, aerospace, education and manufacturing, as adoption rate continues to rise globally, in Asia and as well as in India.

What are your plans for India?

We have established a 3D Printing Experience Center in Bengaluru a few months back, offering total 3D experience and displaying our entire range of products and materials. It will allow the customers to see our innovative technologies in action and realise the values and growing advantages of 3D printing technology to businesses and entrepreneurs. As a trusted industry leader, we recognise the importance of bringing the technology closer to where its customers are, to bridge the gap and ensure higher awareness among local population. In India, we intend to invest in identification of advanced applications (especially direct digital manufacturing system) for which our printing technologies and versatile materials are developed for. In addition, we seek relevant niche applications where additive manufacturing can provide substantial value, and develop a comprehensive solution to address these opportunities. Medical solutions, including surgical tools, medical devices and anatomical replicas, are definitely one of them; and we seek opportunities to promote the various applications that 3D printing can provide to the medical community in India.

What is your message to innovators who wish to explore this technology?

3D printing empowers international corporates and local businesses to unleash creativity and streamline product development process. It addresses the inherent limitations of traditional modelling technologies through its combination of high precision and ability to produce complex geometries in relatively shorter time and lower cost, leading to vast opportunities in rapid prototyping for industries ranging from consumer goods, electronics, education, automotive and machinery as well as tooling. While the technology has been focused on design and manufacturing applications since it was commercialised, it is beginning to show signs of broader adoption, including end-use manufacturing tools and low-volume production parts in areas such as aerospace, defense, education, healthcare, manufacturing,R&D, and automotive to name a few.

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