3D Printing in Medicine and Healthcare

3D printing, more technically known as additive manufacturing, is not as new as people think. It dates back to the 1980s, but in recent years has become a popular manufacturing method for many Xometry customers, including those in aerospace, automotive, architecture, education, jewelry, and art. In medicine and healthcare, it has impressively been used to make prosthetics, medical equipment, and even replacement organs. While Xometry hasn’t 3D printed any organs on-demand (yet?), there are plenty of other applications in this field we have worked on with our medical and healthcare customers.

In this article, we’ll go over everything there is to know about 3D printing in the medical and healthcare industries.

What Is Medicine and Healthcare?

First, let’s briefly cover exactly what we mean by medicine and healthcare. These are umbrella terms that refer to all the practices and procedures involved in the prevention, treatment, relief, and cure of illnesses, diseases, injuries, and other medical conditions, both physical and mental.

“Medicine” is used to describe aspects that doctors and medical professionals have to deal with, like prescribing actual medication, treating patients, performing surgeries, and psychiatric services. “Healthcare” is a broader term that covers medicine as well as support services, like pharmacists, therapists, and even those who design and make medical equipment.

How 3D Printing Technology Helps Medicine and Healthcare?

Traditional manufacturing in healthcare involves a lot of manual labor to create medical equipment from scratch. The process takes the raw materials and removes sections via grinding, carving, and machining until the final product is made. 3D printing has made the process easier, much less labor-intensive, and sometimes quicker and cheaper. 

3D printing doesn’t shape a slab of material to make the products but rather builds them layer by layer using filaments, resins, or fused powders. The product’s designs are typically created using computer-aided design (CAD) software, but it is also possible to create models from 3D scans performed by digital resonance imaging (MRI) machines. In healthcare, you can find both large-scale 3D printing manufacturers like Xometry and point-of-care printing facilities.

A Brief History of 3D Printing in Healthcare

Although it’s not quite 150 years old, the first-ever sign that humans were on the right track when it comes to 3D printing was in the 1860s when François Willème, a French artist, invented the “photo sculpting” method. This involved taking pictures (well, it would have been drawings in those days) of an object from many different angles and then using those images to make a 3D representation. 

A whole hundred and some years later, in 1985, an American from Colorado called Chuck Hall invented the first solid imaging process, also known as stereolithography. This was the first step towards the creation of 3D printers. The healthcare industry started using 3D printing in 2000, and a year later the first synthetic scaffolds for human bladder tissue were 3D printed. In 2008, the first-ever 3D-printed prosthetic leg was made.

Since then there have been many advancements in relation to 3D printing in medicine and healthcare. Blood vessels were 3D bioprinted (a process integrating living cells and biomaterials) in 2009, and 3D-printed human liver tissue was commercially launched in 2014. Scientists started bioprinting hearts and lung sacs in 2019. A year later, British biotech company FABRX brought out a personalized medicine-making machine called M3DIMAKERTM. The sector has only advanced since then, with 3D printing being commonplace within medicine and healthcare.

What Are the Things that the 3D Printer Can Do for Medicine and Healthcare?

3D printing has been massively adopted in the medical and healthcare industries, in large part due to the fact that everything can be customized and patient-specific. These include spinal and orthopedic implants, prosthetic limbs, sockets, and parts, dental crowns, bridges, and other orthodontic devices, drug formulations, and delivery devices (i.e., inhalers, patches, and implants), hearing aids, and detailed anatomical models based on real patients and their personal needs.

But that’s not all! It’s commonly used for specialized and patient-specific surgical tools, procedural guides, and even facial reconstruction. What’s more, quick and precise design adjustments can be made using the surgeons’ valuable feedback. 3D-printed implants are made via many different 3D printing processes in a variety of materials—both of which we will cover further down. For now, let’s take a more in-depth look at some of these applications. 

Implants

Being able to quickly and accurately design and produce customized implants for patients, including dental, spinal, and hip implants, has greatly improved the world of medicine. These personalized parts have the ability to reduce surgery time, complications, having to manually alter standard-sized implants, and the number of invasive bone graft surgeries that doctors have to carry out. All these factors lead to speedier patient recovery and greater chance of success.

Prosthetics

The ability to personalize 3D-printed prosthetics is undoubtedly one of the most impressive ways the method is being used in healthcare, and it has proved to be a total game-changer for amputees. These parts, which include arms and legs, perfectly match the patient’s body for greater comfort and functionality. Traditional prosthetics and their components are notoriously expensive (anywhere from $1,500 to $8,000) and need extensive and rather invasive regular manual adjustments. Not to mention that they take a long time to be ordered and made.

A 3D-printed prosthetic is often more cost-effective. It also has a quick turnaround time (in some cases as little as a day) and requires much less adjusting thanks to its being completely bespoke. These factors are particularly useful for children who quickly outgrow their prosthetics. 3D printing also helps make the not-very-pleasant process a little more tolerable for children and adults alike as they get to choose the different colors, designs, and styles of their prosthetics.

Anatomical Replicas

In addition to prosthetics, anatomical replicas for use in education, training, and pre-surgery planning can be created. These prints very closely, if not precisely, mimic real organs that are designed from the patient’s actual imaging data to allow the practitioners to rehearse their surgeries before the big event. Complicated surgeries can be simulated, allowing doctors and trainees to improve their skills and confidence for fewer complications, and a greater chance of success. At Xometry we offer full-color printing via PolyJet 3D printing technology, which allows us to create life-like replicas with realistic textures and colors. You can learn more about that technology on our PolyJet service page.

Organ and Tissue Printing

Bioprinting, not a service Xometry offers, has been used to create scaffolds resembling human tissue have been the first step in the manufacturing of 3D-printed organs and tissues. While 3D-printed organs, like livers and kidneys, are not entirely mainstream yet, a lot of progress is being made. Researchers are constantly working on new technologies and approaches to bring these out as soon as possible. These machine-made organs have the potential to save millions of lives as ailing folk won’t need to be put on long waiting lists or just hope for the best.

Other Applications

For greater precision and customization, medical devices and tools specifically tailored to each patient can be (and are being) 3D printed within healthcare. The method is also being used for custom medication doses and formulas. This reduces the chance of unpleasant side effects. As an example, the U.S. Food and Drug Administration (FDA) approved Spritam, an epilepsy drug, made via 3D printing. The process improved this medication and made it easier to dissolve than other pills.

How Does the FDA Regulate the 3D Printers Used for Medicine and Healthcare?

The FDA regulates 3D-printed products for use in medicine and healthcare in almost the same way it does for traditionally manufactured products. However, as stated above, it focuses more on the products and the method and doesn’t regulate the printers. The FDA has a different reviewing process depending on the type of product, what it will be used for, and any potential risks. 

The risk level is what the FDA uses to put items into categories. Class I is low-risk and needs minimal oversight, Class II is medium-risk, and Class III is the high-risk category that requires the most thorough testing and review.

What Are the Advantages of 3D Printing in Medicine and Healthcare?

Medicine and healthcare have been one of the first industries to adopt 3D printing technology as the advantages are endless. It doesn’t take a rocket scientist to see just how important 3D printing already is, and has the potential to be, in healthcare. The main goal here is to improve patient care and health. Personalized parts, medicines, drug delivery methods, and other solutions based on each patient’s data from MRI and CT scans are greatly changing the way patients are being treated, lowering their recovery times and potential complications, and increasing the chances of success. 

3D-printed parts in healthcare are designed to be more compatible with the human body than traditionally made parts and can be more easily adapted to a patient’s exact anatomy and needs. The process allows for the quick creation of necessary medical items, including on-demand manufacturing, which reduces the need for large and expensive inventories, and lowers patient wait times. The speed of 3D printing also means that any design adjustments needed after testing won’t take a long time either. In emergencies, this is an invaluable perk.

Compared to usual manufacturing methods, 3D printing is a lot more eco-friendly and keeps waste to a minimum. It’s also much more cost-effective as not very much manual labor or tools are needed, other than the printer and the material. Thanks to the materials used in 3D printing, parts can be made much lighter and sturdier than traditionally manufactured ones. Surgeons and those still in education can practice surgeries on life-like 3D printed parts, and test new devices and treatments without having to go through the typically long delivery wait times.

As this method gains popularity, it will make healthcare much more accessible for patients, and enable facilities and professionals to do their jobs much more quickly and efficiently.

What Are the Disadvantages of 3D Printing in Medicine and Healthcare?

While the advantages of 3D printing in healthcare far outweigh the disadvantages, there are a few snags that will hopefully be ironed out and improved as the technology advances. For starters, the range of materials suitable for 3D printing in the field is rather limited in comparison to traditional manufacturing methods. There are also still issues with the consistency in the quality of prints. 

In addition, just like with regularly made healthcare items, 3D-printed ones need to go through a copious FDA approval process to ensure they meet all the necessary standards, like quality, safety, and efficiency. More than 100 3D-printed medical items have been already approved by the FDA, but these are mostly medical devices (i.e., orthopedic implants), and not medicines. Professionals in the industry have expressed that the FDA really needs to make relevant adjustments to these regulations to be more specific for 3D printing.

The main problem when it comes to FDA approval is that it focuses more on the 3D-printed products and not the printers, and there aren’t any specific guidelines on how to safely make medicines. Despite the lack of guidance, these products still have to go through the same lengthy testing and approval process as other medical products.

Another issue is that anyone can make medical 3D products if they have a good printer, including those who don’t really have a good grasp on all the FDA’s rules and regulations. This makes oversight quite the feat when compared to trusted 3D printing manufacturers like Xometry. Point-of-care 3D-printed products are also hard to monitor since they are made directly at the hospital or clinic and not at a manufacturing facility. 

Further complicating matters, there doesn’t seem to be a clear distinction between medical products and practice. The boards of some medical facilities do all the overseeing when it comes to practice, while the FDA takes care of the products, but with 3D printing, the lines get a little blurred. As an example, if a hospital 3D prints a customized surgical tool, it can be hard to tell whether the oversight is the responsibility of the board or the FDA.

What Types of 3D Printers Are Used in Healthcare?

There are a handful of different 3D printer types used for making healthcare products, each with its own set of pros and cons. Here are the most commonly used 3D printers in the medical industry.

Stereolithography (SLA)

These printers make products by curing liquid resin with lasers. We offer this process for making high-resolution and precise products with smooth finishes. It’s useful making things like prototypes and anatomical models, but it does need some post-processing.

Selective Laser Sintering (SLS)

These printers are preferred for complex and intricate mechanical and custom parts. They have high-powered lasers that fuse powdered material to make the final product. They often print in nylon and other polyamides (PA). SLS nylon prints can be sterilized with the right equipment thanks to the materials ability to handle high heat, making it beneficial for medical devices. Generally these printers are meant for industrial spaces as they are very large and complex machines, however at Xometry we offer it as a standard service, making it easily accessible.

Fused Deposition Modeling (FDM)

After melting a thermoplastic filament, an FDM printer strategically extrudes it onto it’s build platform and builds up layer by layer, until the final product is built. It’s cost effective and great for basic prototypes and simple parts. Its lower resolution means that it won’t be the best choice for complex products, and will likely need more post-processing. The microgaps between the layers also present a challenge for sterilization, so this technology is best kept to prototyping purposes.

Direct Metal Laser Sintering (DMLS)/Selective Laser Melting (SLM)

Both these types of printers have lasers that melt metal powder to create strong and biocompatible parts, like custom implants. They are, however, almost exclusively meant for industrial environments and to be operated by experts. They are also very costly machines to purchase and operate. We offer DMLS printing to our customers so they have an easy way of accessing this powerful printing technology.

What 3D Printing Materials Are Used in Healthcare?

There are many different materials used for 3D printing in healthcare, all of which need to meet strict safety, quality, and efficiency standards. They must be strong, durable, sterilizable, corrosion-resistant, and lightweight. Not all materials that are 3D printer-compatible are safe for medical use, but here’s a list of the most commonly used 3D printing materials in medicine and healthcare that can meet the necessary requirements:

• Nylon PA-12
• PC-ISO
• ABS M30i
• Titanium
• Cobalt chrome
• Stainless steel
• Thermoplastic polyurethane (TPU)
• Polylactic acid (PLA)
• Polyetheretherketone (PEEK)
• Polyetherketoneketone (PEKK)
• Polymethyl methacrylate (PMMA)
• Bioceramics
• Polyethylene glycol (PEG)

To learn more, see our full guide on Materials Used in 3D Printing.

What Are Other Real World Applications of 3D Printing?

There are many other commercial applications of 3D printing beyond medicine and healthcare, including:

1. Aerospace: 3D printing is used to produce lightweight, high-strength components for aerospace applications, including rocket engines and satellite parts.
2. Automotive: Car manufacturers use 3D printing to produce prototypes, customized parts, and even entire vehicles. Vehicle components can be 3D printed and assembled, this includes engine components, interior design components, etc. 
3. Architecture: Architects use 3D printing to create scale models of buildings and urban environments, allowing for more accurate and detailed planning.
4. Education: 3D printing is used in educational settings to teach students about engineering, design, and manufacturing, and to allow them to create their own designs.
5. Jewelry: 3D printing is used to create custom jewelry designs with intricate details and unique shapes.
6. Art: 3D printing is used in the creation of sculptures, installations, and other forms of art, allowing artists to experiment with new materials and shapes.

What Are the Challenges of Using 3D Printing for Medicine and Healthcare?

The main challenges for FDA oversight of 3D printing in the medical industry are related to the decentralized manufacturing of customized medical products using 3D printing technology. Organizations or individuals who might have limited experience with following FDA regulations can manufacture implantable medical devices or other medical products using 3D printing. When 3D printing is used in centralized facilities by registered manufacturers subject to FDA inspection, oversight responsibility is clear. However, oversight becomes less clear when 3D-printed medical products are manufactured at the point of care.

The FDA is responsible for ensuring that manufacturers comply with good manufacturing practices and that the products they create meet the statutory requirements for safety and effectiveness. The agency needs to adapt regulatory requirements to ensure that 3D-printed medical products are fit for their intended use and safe for patients.

It is also important to note that the actual practice of medicine is primarily overseen by medical boards, rather than the FDA. However, in certain clinical scenarios which use 3D printing, it may not always be easy to distinguish between the product and the practice of medicine.

How Safe Is 3D Printing Technology for Medicine and Healthcare?

The safety of 3D printing technology in medicine and healthcare depends on a number of factors, including: the materials used, the design of the product, and the production process. In general, 3D printing technology is considered safe when used appropriately and in accordance with established guidelines and standards. For example, medical devices produced through 3D printing must meet the same safety and efficacy standards as those produced through traditional manufacturing methods. However, there are some potential safety concerns associated with 3D printing in medicine and healthcare. For example, there is a risk of contamination if the printing process is not properly controlled or if the materials used are not sterile. There is also a risk of mechanical failure if the product is not designed and produced correctly.

To address these concerns, regulatory agencies such as the FDA have established guidelines and standards for the design, production, and testing of 3D-printed medical devices. Healthcare providers and manufacturers must follow these guidelines to ensure the safety and efficacy of their products.

Do Medicine and Healthcare Benefits the 3D Printing Technology?

Yes, medicine and healthcare greatly benefit from 3D printing technology. The medical industry has been one of the early adopters of 3D printing technology, and the benefits are numerous. The ability to create customized and patient-specific medical devices, prosthetics, implants, and models with 3D printing technology has revolutionized the way healthcare providers approach patient care. This technology has enabled faster production, reduced costs, and improved patient outcomes.

Moreover, 3D printing technology has allowed for greater accuracy in surgical planning and improved medical education. 3D-printed models of patient anatomy can be used to plan surgical procedures, and medical students and residents can learn about anatomy, surgical procedures, and medical devices through the use of 3D-printed models. 3D printing technology has also facilitated the development of new and innovative medical devices and products, and it has allowed for greater accessibility to medical devices and prosthetics, especially in remote or low-income areas.

Is the 3D Printed Artificial Limb not Strong?

Yes, 3D-printed artificial limbs can be strong and durable. Their strength depends on several factors such as the materials used, the design of the limb, and the intended use of the limb. With advancements in 3D printing technology and materials, it is now possible to create prosthetics and orthotics that are just as strong and durable as conventionally manufactured ones. For example, 3D-printed prosthetics can be made using materials such as titanium or carbon fiber, which are known for their strength and durability.

Are the Materials Used by 3D Printers Safe for Medical Use?

No, not all materials used by 3D printers are safe for medical use. However, there are a number of materials that have been approved for use in medical applications. For example, biocompatible materials such as medical-grade titanium and cobalt-chromium alloys are used in the production of implants and other medical devices. There are also biocompatible polymers like polyethylene terephthalate glycol (PETG) and polylactic acid (PLA) that are commonly used in the production of medical devices, prosthetics, and orthotics.

It is important to note that the safety of materials used in 3D printing depends on several factors beyond their chemical composition, such as the intended use of the product, the type of printer, the printing process, and the quality of the materials. Materials that are not properly tested or approved for medical use can potentially cause harm to patients.

Copyright and Trademark Notice

1. M3DIMAKERTM is owned by FabRx Ltd., a pharmaceutical biotechnology spin-out from University College London (UCL)

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