3D printing is increasingly attractive to the medical industry due to its design freedom and transformative benefits for numerous medical applications such as external wearables, point-of-care (POC) tools, medical devices and implants.

BASF ForwardAM

The inherent characteristics of additive manufacturing make it ideal for the medical field, as it enables rapid and customizable production, and is suitable for sophisticated, complex designs. While traditionally manufactured, highly individualized devices require expensive special tools, 3D printers require only a single digital file, enabling simpler and more economical custom designs. This flexibility is critical for customizing medical components such as prostheses, orthoses, and insoles to fit the patient's anatomy.

With the ever-increasing demand for environmental sustainability and the introduction of new directives and regulations on product audits such as medical devices, the medical industry needs to find innovative ways to respond. Fortunately, additive manufacturing brings a wide range of sustainability benefits, helping to reduce waste, reduce energy consumption, and reduce the use of raw materials. For example, 3D printing is an additive process that builds objects precisely layer by layer, which means that the amount of scrap generated during manufacturing for medical applications is significantly reduced compared to traditional manufacturing methods.

However, unlocking the full potential of additive manufacturing in healthcare still faces challenges. This innovative technology offers a great deal of freedom, but achieving it requires expert guidance, specialized tools and high-performance materials.

Forward AM provides medical industry customers with a one-stop solution that includes a broad product portfolio with deep material expertise, end-to-end virtual engineering and industry-leading additive manufacturing process expertise.

Forward AM will explore key elements of additive manufacturing in medical applications

1.Certifications and Specifications for Medical Applications

2.Additive Manufacturing Design Processes for the Medical Industry

3.Additive Manufacturing Material Selection for Medical Projects

1.This table is a list of Forward AM materials and their passed USP Class VI biocompatibility testing requirements.

The above experiments were carried out on parts printed with Forward AM material on Forward AM's 3D printing equipment, with control of the printing process and post-processing of the parts. Test results are a combination of printer, process and print cleanliness, so results obtained by customers may vary. Of course, Forward AM assists customers in selecting the appropriate material and manufacturing process to obtain an item that matches the intended application.

2.Additive Manufacturing Design Processes for the Medical Industry

Process of custom brace for injured limb (wrist in this 

Forward AM has dedicated services and solutions to define and support the entire additive manufacturing design workflow for medical applications. This division specializes in part design optimization, part and process performance simulation, best-fit 3D printing process consulting, low-load part behavior testing, and post-processing including coatings. Post-processing of 3D printed stents can include coating, adding fillers, mechanical grinding, and adding parts such as Velcro.

3.Additive Manufacturing Material Selection for Medical Projects

BASF's virtual engineering suite Ultrasim® is a powerful digital workflow that supports an intelligent search for the optimal geometry to meet the application's unique mechanical performance requirements. This makes it possible to create crystalline structures that can provide different levels of stiffness in different areas and even simulate absorption and rebound behavior to optimize comfort and performance in medical applications such as insoles.

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Several areas in the medical industry have benefited from additive manufacturing. This technology opens up new avenues for delivering personalized care and better performing medical devices. With engineering-grade additive manufacturing materials, extensive virtual engineering experience, and rigorous in-house testing processes, Forward AM helps customers develop and validate medical applications to create spec-compliant, application-friendly, comfortable parts that enable More affordable and faster mass production.