Skip to main content
Sister Publication Links
  • Sustainable Plastics
  • Rubber News
Subscribe
  • Sign Up Free
  • Login
  • Subscribe
  • News
    • Processor News
    • Suppliers
    • More News
    • Digital Edition
    • End Markets
    • Special Reports
    • Newsletters
    • Resin pricing news
    • Videos
    • Injection Molding
    • Blow Molding
    • Film & Sheet
    • Pipe/Profile/Tubing
    • Rotomolding
    • Thermoforming
    • Recycling
    • Machinery
    • Materials
    • Molds/Tooling
    • Product news
    • Design
    • K Show
    • Mergers & Acquisitions
    • Sustainability
    • Public Policy
    • Material Insights Videos
    • Numbers that Matter
    • Automotive
    • Packaging
    • Medical
    • Consumer Products
    • Construction
    • Processor of the Year
    • Best Places to Work
    • Women Breaking the Mold
    • Rising Stars
    • Diversity
    • Most Interesting Social Media Accounts in Plastics
  • Opinion
    • The Plastics Blog
    • Kickstart
    • One Good Resin
    • Pellets and Politics
    • All Things Data
    • Viewpoint
    • From Pillar to Post
    • Perspective
    • Mailbag
    • Fake Plastic Trees
  • Shop Floor
    • Blending
    • Compounding
    • Drying
    • Injection Molding
    • Purging
    • Robotics
    • Size Reduction
    • Structural Foam
    • Tooling
    • Training
  • Events
    • K Show Livestream
    • Plastics News Events
    • Industry Events
    • Injection Molding & Design Expo
    • Livestreams/Webinars
    • Editorial Livestreams
    • Ask the Expert
    • Plastics News Events Library
    • Processor of the Year submissions
    • Plastics News Executive Forum
    • Injection Molding & Design Expo
    • Plastics News Caps & Closures
    • Women Breaking the Mold Networking Forum
    • Plastics in Automotive
    • PN Live: Mergers and Acquisitions
    • Polymer Points Live
    • Numbers that Matter Live
    • Plastics in Politics Live
    • Sustainable Plastics Live
    • Plastics Caps & Closures Library
    • Plastics in Healthcare Library
    • Women Breaking the Mold Networking Forum Library
  • Rankings & Data
    • Injection Molders
    • Blow Molders
    • Film Sheet
    • Thermoformers
    • Pipe Profile Tubing
    • Rotomolders
    • Mold/Toolmakers
    • LSR Processors
    • Recyclers
    • Compounders - List
    • Association - List
    • Plastic Lumber - List
    • All
  • Directory
  • Resin Prices
    • Commodity TPs
    • High Temp TPs
    • ETPs
    • Thermosets
    • Recycled Plastics
    • Historic Commodity Thermoplastics
    • Historic High Temp Thermoplastics
    • Historic Engineering Thermoplastics
    • Historic Thermosets
    • Historic Recycled Plastics
  • Custom
    • Sponsored Content
    • LS Mtron Sponsored Content
    • Conair Sponsored Content
    • KraussMaffei Sponsored Content
    • ENGEL Sponsored Content
    • White Papers
    • Classifieds
    • Place an Ad
    • Sign up for Early Classified
MENU
Breadcrumb
  1. Home
  2. News
April 02, 2013 02:00 AM

HEADS UP: 3-D printing provides custom-made craniums

Gayle S. Putrich
  • Tweet
  • Share
  • Share
  • Email
  • More
    Reprints Print
    Oxford Performance Materials
    OPM's custom-made, patient-specific OsteoFab cranial implant device

    WASHINGTON — If, after a nasty accident, you have to have a plate implanted in your skull, wouldn't you prefer to have one that is custom made?

    Thanks to polyetherketoneketone polymers, 3-D printing technology and the Food and Drug Administration's approval of the OsteoFab patient-specific cranial device, that is entirely possible.

    Oxford Performance Materials, in South Windsor, Conn., traditionally sold PEKK as a raw material or in a semi-finished form, but the company began developing additive manufacturing technologies in 2006 after reading several articles by surgeons saying, "If only we could … ," according to OPM President and CEO Scott DeFelice.

    OPM started by looking at the powder-based 3-D printing process and, after six years and "many millions" in internal investment, came up with a cranial implant manufacturing process for custom building a product to fit each patient.

    After a craniotomy, CT scans from the hospital are sent to Connecticut, where the OPM engineering team uses them to create printable computer-aided-design flies with all the details, down to the screw holes, for implantation. A surgeon electronically reviews and approves the design and it is printed in OPM's biomedical clean rooms, built in 2011, using a selective laser sintering 3-D printer.

    "Once we get a file, we can get it to a customer within two weeks," DeFelice said. "The actual manufacturing time is about a day, but there are lots of quality control and regulatory requirements to be met."

    The entire treatment, from arrival in the surgical room to the final implantation, can take several months and cost between $8,000 and $15,000, but it provides benefits unmatched by other medical devices, DeFelice said. Since the implant is custom-built to fit the patient, the surgery itself is quicker with no last-minute device modifications, which saves money and helps reduce the chance of complications, he said. As an implantable polymer, PEKK is biocompatible, mechanically similar to bone, osteoconductive and radiolucent, cutting down on noise in future X-rays.

    While most of the magic behind OsteoFab is in the proprietary PEKK polymer and the manufacturing process, the FDA "approves devices, not a polymer," so OPM has to map out future plans one device at a time.

    "We went with the cranial implant for first approval because the need was the most compelling," DeFelice said. "But this is just the beginning. There's really no part of the body that will go untouched by this."

    Looking ahead, DeFelice is interested in applying the OsteoFab technology to the diabetic foot market, replacing bones that have virtually turned to powder because of diabetes, as well as spinal trauma and radical joint revision.

    In the meantime, OPM plans to continue offering its proprietary implant-grade PEKK in bars and pellets for injection molding and machining.

    "We're migrating from being a material supplier — which we still do — to an orthopedic supplier directly to hospitals.," DeFelice said. "We still have a very broad biomedical product line that's got well-established proc­essability and good regulatory approval. There are three cleared grades, barium sulfate, carbon and then OsteoFab," DeFelice said, which is uncommon among manufactures, who generally prefer to deal only with OEMs and refuse to sell directly to molders.

    "So the molders have been pushed out and haven't been able to do development. That's something we do differently," he said. "We will sell to molders and other smart people looking at problems, not just the OEMs, who don't always have a lot of processing knowledge."

    RECOMMENDED FOR YOU
    Industry sees Biden bioplastics goal as serious signal
    Letter
    to the
    Editor

    Do you have an opinion about this story? Do you have some thoughts you'd like to share with our readers? Plastics News would love to hear from you. Email your letter to Editor at [email protected]

    Most Popular
    1
    Biden sets US goal to replace 90% of plastics with biomaterials
    2
    Industry sees Biden bioplastics goal as serious signal
    3
    Report urges treaty to regulate plastics like pharmaceuticals, limit growth
    4
    One injured in explosion at Ineos cumene plant in Texas
    5
    Engineering resin prices close the first quarter with a drop
    SIGN UP FOR OUR FREE NEWSLETTERS
    EMAIL ADDRESS

    Please enter a valid email address.

    Please enter your email address.

    Please verify captcha.

    Please select at least one newsletter to subscribe.

    Get our newsletters

    Staying current is easy with Plastics News delivered straight to your inbox, free of charge.

    Subscribe today

    Subscribe to Plastics News

    Subscribe now
    Connect with Us
    • LinkedIn
    • Facebook
    • Twitter
    • Instagram

    Plastics News covers the business of the global plastics industry. We report news, gather data and deliver timely information that provides our readers with a competitive advantage.

    Contact Us

    1155 Gratiot Avenue
    Detroit MI 48207-2997

    Customer Service:
    877-320-1723

    Resources
    • About
    • Staff
    • Editorial Calendar
    • Media Kit
    • Data Store
    • Digital Edition
    • Custom Content
    • People
    • Contact
    • Careers
    • Sitemap
    Related Crain Publications
    • Sustainable Plastics
    • Rubber News
    • Tire Business
    • Urethanes Technology
    Legal
    • Terms and Conditions
    • Privacy Policy
    • Privacy Request
    Copyright © 1996-2023. Crain Communications, Inc. All Rights Reserved.
    • News
      • Processor News
        • Injection Molding
        • Blow Molding
        • Film & Sheet
        • Pipe/Profile/Tubing
        • Rotomolding
        • Thermoforming
        • Recycling
      • Suppliers
        • Machinery
        • Materials
        • Molds/Tooling
        • Product news
        • Design
      • More News
        • K Show
        • Mergers & Acquisitions
        • Sustainability
        • Public Policy
        • Material Insights Videos
        • Numbers that Matter
      • Digital Edition
      • End Markets
        • Automotive
        • Packaging
        • Medical
        • Consumer Products
        • Construction
      • Special Reports
        • Processor of the Year
        • Best Places to Work
        • Women Breaking the Mold
        • Rising Stars
        • Diversity
        • Most Interesting Social Media Accounts in Plastics
      • Newsletters
      • Resin pricing news
      • Videos
    • Opinion
      • The Plastics Blog
      • Kickstart
      • One Good Resin
      • Pellets and Politics
      • All Things Data
      • Viewpoint
      • From Pillar to Post
      • Perspective
      • Mailbag
      • Fake Plastic Trees
    • Shop Floor
      • Blending
      • Compounding
      • Drying
      • Injection Molding
      • Purging
      • Robotics
      • Size Reduction
      • Structural Foam
      • Tooling
      • Training
    • Events
      • K Show Livestream
      • Plastics News Events
        • Plastics News Executive Forum
        • Injection Molding & Design Expo
        • Plastics News Caps & Closures
        • Women Breaking the Mold Networking Forum
        • Plastics in Automotive
      • Industry Events
      • Injection Molding & Design Expo
      • Livestreams/Webinars
        • PN Live: Mergers and Acquisitions
      • Editorial Livestreams
        • Polymer Points Live
        • Numbers that Matter Live
        • Plastics in Politics Live
        • Sustainable Plastics Live
      • Ask the Expert
      • Plastics News Events Library
        • Plastics Caps & Closures Library
        • Plastics in Healthcare Library
        • Women Breaking the Mold Networking Forum Library
      • Processor of the Year submissions
    • Rankings & Data
      • Injection Molders
      • Blow Molders
      • Film Sheet
      • Thermoformers
      • Pipe Profile Tubing
      • Rotomolders
      • Mold/Toolmakers
      • LSR Processors
      • Recyclers
      • Compounders - List
      • Association - List
      • Plastic Lumber - List
      • All
    • Directory
    • Resin Prices
      • Commodity TPs
        • Historic Commodity Thermoplastics
      • High Temp TPs
        • Historic High Temp Thermoplastics
      • ETPs
        • Historic Engineering Thermoplastics
      • Thermosets
        • Historic Thermosets
      • Recycled Plastics
        • Historic Recycled Plastics
    • Custom
      • Sponsored Content
      • LS Mtron Sponsored Content
      • Conair Sponsored Content
      • KraussMaffei Sponsored Content
      • ENGEL Sponsored Content
      • White Papers
      • Classifieds
        • Place an Ad
        • Sign up for Early Classified