AK Medical to meet the need for orthopedic implants with a fleet of 8 GE Additive EBM Systems

Image: GE Additive

With the goal of expanding its focus into other orthopedic areas beyond bone joints, AK Medical relies on an additional fleet of eight (8) GE Additive Electron Beam Melting systems.

AK Medical is a China-based company that specializes in orthopedic implant industry. As an early adopter of additive manufacturing, the company has been developing a broad range of customized implants and devices.

While meeting the stringent requirements of the medical industry including the National Medical Products Administration, the company’s new method for producing medical devices has been acknowledged by several orthopedic surgeons across the country.

The reason lies in the big difference between traditional & additive manufacturing.

Conventional manufacturing technologies only enable the fabrication of fixed models in batches and requires several steps before getting the final end-product. These steps include for instance, product design to mold design, mold manufacturing, blank die-casting, processing, and post-processing.

Since bone morphology varies from one person to another, implants are usually more likely to require adjustments and other operations, not to mention that their insertion can be more complex. Indeed, to adapt to adapt to the prosthesis in case there is no perfect compatibility, the surgeon can make an incision into the patient’s bone, which inevitably results in the loss of bone tissue.

Furthermore, according to experts, spinal implants need to be fixed into place at the front and rear of the abdomen during surgery, and an external fixation device is also needed post-surgery to maintain stability. As a result, some patients may need extended bed rest – typically three months – before the device is removed.

What changes with additive manufacturing

Developed by Arcam AB, a GE Additive company, EBM is a unique rapid manufacturing method that has proved out its capabilities for several industries including the medical industry. The technology is used by several medical companies across the world including Amplifying that has dedicated its core business to the manufacturing of 3D printed orthopedic implants.

Not only does this process helps operators reduce lead times, but it also allows for customizable manufacturing which is crucial to develop a device that fits the patient morphology. In this case, the trabecular structure of the implant is built directly into the part, leading to increased levels of integration between the implant and bone.

At the technical level, the process does not require all the steps of a conventional manufacturing process, and EBM is a sustainable manufacturing process in its DNA.

 According to the operator, GE Additive’s technology delivers high melting efficiency, enables stacking while reducing the need for post-heat treatment. The manufacturer would save the cost of an acetabular cup on average by 38% when compared to other AM technologies

We have used EBM technology for more than a decade, so when we recently needed to invest in new machines, we naturally opted for the Q10plus,” said Mr. Li Zhijiang, chairman, chief executive officer and executive director at AK Medical. “The Q10plus system provides a user-friendly interface, a higher precision of processing, and better-quality products. It helps us improve the cost efficiency of both standard production and small-scale customized production.”

We look to the future full of confidence,” said Mr. Li. “Additive technology itself is tremendously advantageous in terms of cost, and personalized customization is increasingly becoming an industry trend. And when you begin think of it in combination with CT, nuclear MRI, software, the Internet, 5G and many other technologies, then additive is likely to unleash greater potential to boost the entire medical industry.

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