Customized titanium implants are now manufactured on-site at MU-Varna thanks to integrated 3D solutions from SpaceCAD

Medical University - Varna officially introduces one of the most advanced technologies in the world of surgery and dentistry - 3D printing of titanium and cobalt-chrome for the production of custom implants. The project was implemented with the help of strategic technology partner SpaceCAD, a leader in the field of industrial 3D printing and digital engineering solutions. "With the implementation of 3D Systems' DMP Flex 200 metal 3D printer and the comprehensive software package for processing, design and manufacturing, Bulgaria is taking an important step towards the future of personalized medicine," SpaceCAD commented to BalkanEngineer.com.

From classic implants to personalized surgery

For decades, surgeons relied on standard mass-produced implants designed to cover a wide range of clinical cases. In complex situations — severe pelvic fractures, tumor resections, or complex joint revisions — doctors were often faced with the difficult task of "adjusting" the patient's anatomy to the implant, rather than the other way around. This compromise inevitably leads to a higher risk of complications, a longer recovery period and sometimes to unsatisfactory functional and aesthetic results. "Until recently, we were limited to models made of polymers, which are mainly used for planning. Now we can produce direct implants for the human body - precise, individual and perfectly tailored to the specific patient," emphasized Prof. Dr. Dimitar Raykov, Rector of MU-Varna.

Thanks to the technologies that SpaceCAD has supplied and integrated, implants can be designed specifically to meet the patient's needs, from CT scans to the final titanium component.

Micron-scale precision

The new metal additive technology uses the Direct Metal Laser Sintering (DMLS) method, in which a laser melts metal powder layer by layer, creating complex, robust and biocompatible structures. In this way, the implant can be designed to fully match the structure of the bone. "Layer by layer, the whole detail is being built. The laser melts metal dust particles 30 μ thick, which is three times thinner than a human hair. Thus, we get an extremely strong and geometrically perfect implant that corresponds to the virtual model to the last detail," explained Assoc. Dr. Eng. Tsanka Dikova, project manager. The system allows the production of medical implants from titanium alloys Ti6Al4V, as well as cobalt-chromium, widely used in orthopedics, maxillofacial surgery, oncology and dentistry.

Read the entire material in Engineer.bg HERE.

Photo source: SpaceCAD, ©Engineer BG via Canva.com