China showcases large 3D printed metal frames for new generation of military aircraft

[cirr]

Chinese woman receives the world's first 3D printed titanium sternal

July 9, 2015 | By Alec

Though we here at 3ders.org enjoy speculating about the ongoing revolution that 3D printing is causing the medical world, things must look a bit different when you’re a patient. Perhaps unsprisingly, Chinese patient Mrs. Gu described her 3D printed implant as a ‘miracle’ and as a ‘protector'. The 54-year-old woman from Luoyang City in China recently underwent surgery in the TangDu Hospital in Xi’an, becoming the first patient in the world to receive a 3D printed titanium sternal implant.

This miraculous sense of relief is perhaps unsurprising. With a tremendous sense of relief, she said, ‘my heart now has a sturdy guardian’. Mrs. Gu also felt very very lucky that this technology was available. ‘The magical of combination of high quality technology and advanced medical knowledge now really exists.’ And if you’re a patient with a dangerous condition, it definitely seems miraculous. The 54-year-old was diagnosed with a tumor in her sternum a year ago, which quickly caused a lot of medical problems. Excessive growth quickly caused the tumor to press on her chest, causing pain, tightness, a shortness of breath and other complications.

Visiting a number of hospitals with her husband, most doctors advised the dangerous removal of the sternal. Upon visiting the TangDu Hospital of the Fourth Military Medical University, they met Wang Xiaoping, the Deputy Director of the thoracic surgery department. As he explained, their chest surgical experts discussed possible treatment methods at length. The problem was that the tumor was now about six or seven centimeters in size, meaning surgery was urgent. However, removal in turn could cause large defects in the chest region, including respiratory problems, while also severely impacting her appearance.

‘If the chest bone is resected, the heart area loses its ‘protective’ walls,’ Wang Xiaoping explained. ‘With traditional surgical resection of the substernal, patients cannot go to crowded places or even embrace loved ones, and patients with serious conditions may faint. That’s why a traditional resection is not an ideal option.’ The professor further said that, after a lot of discussion, it was decided to go for a revolutionary option: after removal of the tumors, they would implant a 3D printed titanium alloy sternum, which is an exact copy of the patient’s previous chest structure.

It is believed that this is the first time a 3D printed titanium sternum implant was surgically used. ‘We have never heard of any case about 3D printed titanium sternal implants. We contacted the relevant authorities and discovered that this is the first time that 3D printed titanium implants were ever used for sternal tumors and diseases,’ he added.

But as you might expect, this was relatively difficult to manufacture. As the hospital’s Ultrasound Diagnostic Department Professor and 3D printing team leader Cao Tiesheng said, they began working on a suitable replacement program as soon as risk assessment was completed. Problematically, the size of the tumor made it difficult to get precise data – something which massively complicates design (as all of us must have experienced). ‘Everybody has a different bone structure and we have thought about a lot of ways to solve this problem. Eventually, we found a lady with similar characteristics, such as height, weight and so on, to stand in for her. We collected her sternum data and combined that with what we know of Mrs. Gu’s sternum. After multiple correlations and tests – a process that lasted several weeks – we finally had a working 3D model of her sternum,’ he says.

Professor Cao Tiesheng added that they made a 1:1 scale 3D printed plastic model to fully verify suitability. They subsequently commissioned the State Key Laboratory of Solidification Processing, from the School of Materials Science and Engineering of Northwestern Polytechnical University, to 3D print the implantable titanium sternal model. After manufacturing, the sternum model underwent a series of stringent medical treatments.

Surgery itself took place on June 22, with the patient recovering smoothly and without complications so far. ‘Well now, I don't feel anything at all,’ Gu said when asked about her condition. Her husband jokingly added: ‘with this hard titanium protection, your heart will be more powerful, and you will recover soon.’

3ders.org - Chinese woman receives the world’s first 3D printed titanium sternal | 3D Printer News & 3D Printing News

 

[Tom99]

At this rate, cyborgs will emerge in China very soon. lol

 

[cirr]

MEDPRIN 3D prints world's first biological meningioma ReDura for use in brain surgery

July 21, 2015 | By Alec

While 3D bioprinting innovations sound life-saving and revolutionary, most are still years away from impacting ordinary people in regular hospitals. However, one Chinese company is already implementing a bioprinted product on a large scale across the world. Called MEDPRIN, they have developed the world’s first 3D printed biological meningioma called ReDura – a replica of tissue covering the brain – and are already applying it in surgical rooms across the world.

MEDPRIN is based in Guangzhou, China and was founded by a team of biomedical scientists in 2008 as a developer of regenerative medical materials and devices. Since then, they have grown out to become a global leader in the field of implantable medical devices, and the ReDura is just one of the many products they have released. It’s full name is the ReDura® Biomimetic-Synthetic-Absorbable Dural Substitute, and has already received a number of medical certificates, including from CE and CFDA. It has also reportedly been applied on tens of thousands of cases across the world and it is also believed to be the first applied bioprinted product to come out of China.

So what exactly is the ReDura? With a thickness of only 0.2 mm, it looks like ordinary tissue paper, but is in fact a tissue with extraordinary qualities. Usually, when patients undergo brain surgery, doctor first need to cut through a layer of protective tissue between the skull and the brain. When patching everything up, they 'paste' an artificial Meningioma layer on the area in question and sew everything together. While these have already been widely and successfully used in brain surgeries everywhere, they are not biological and have a tendency to disrupt a patient’s life - as most artificial meningioma layers contain metal parts and will often case security alarms to beep.

Fortunately, this 3D printed biological ReDura doesn’t suffer from these problems, but instead closely resembles the existing membrane and a patient’s autologous cells. It also features an excellent repair effect. While dry, it resembles a white paper, but when wet it begins to resemble a thin rubber surface perfect for use in surgical rooms.

Yuan Yuyu, the chairman of MEDPRIN, explained how they developed this 3D printed material. They begin by taking meninges tissue out of patients themselves to analyze the fiber structure. They will subsequently use 3D printing technology to create artificial meninges structures. Upon implantation, the brain’s blood vessels crawl into the structures. Over a course of up to three months, a completely new Meningioma beings to grow, while the artificial structure naturally degrades.

It has already been very successfully applied to thousands of patients, Professor Xu Tao from Tsinghua University, the CTO of Medprin, adds. ‘In March 2011, the product 2011 received the European Union CE certification, and was sold to dozens of countries in Europe and America, and has been used in world renowned hospitals such as Cambridge University Hospital. So far, no reports of adverse reactions have been made,’ he said. ‘The core membrane adopts the most advanced 3D printing based bio-regenerative medical platform, and has launched after five years of development.’

The history of this product goes all the way back to 2001, when Xu Tao was still a PhD student in the US at the team of Thomas Boland – the father of 3D bioprinted organs. In 2003, Xu Tao was successful in live cell printing with a survival rate of more than 90% (a patent was granted two years later). In 2009, Xu Tao teamed up with Yuan Yuyu from Clemson University to found the first bioprinting company in China.

As Xu Tao explains, the key difference between bio 3D printing and traditional printing is in the printhead used. ‘There are two kinds of printhead used in bio 3d printing: One is filled with human cells called "bio-ink", with the quantity being in the millions; the other is mainly composed of a 3D printable water gel called “Biology paper”, which can be used as a support for cell growth.’ When printing out membranes, he says, the machine sprays out a fiber-like ink onto biological paper that simulates the collagen structures found in body. Forming hundreds or even thousands of layers of molecular membrane, the result can be adapted to a human environment. Key is the use of a patient’s own autologous cells to prevent immune reactions. In time, this will allow on-demand organ printing to take place.

In case of the ReDura membrane, they only produce tissue of up to 0.2 mm in thickness, but that is all that is needed for a protective layer between the skull and the brain. According to the company, doctors could just use ReDura on the defect areas and sow it together. ‘ReDura is hydrophobic with a more than 90 contact angle that acts as a watertight barrier for the prevention of cerebrospinal fluid (CSF) leakage,’ writes the company. ‘ReDuraTM is manufactured with FDA approved degradable material poly-L-lactic acid which has been extensively tested to prove the biocompatibility and non-toxicity.’

Yuan Yuyu further stated that the ReDura is eventually absorbed into the body. ‘Simply put ReDura provides the bracket in which cells and tissue can grow. About two months after a meningeal tissue has grown, the ReDura begins to slowly degrade into toxic-free carbon dioxide and water,' he says. ‘ReDura is fully degraded and absorbed, leaving no foreign body in-situ and is replaced by regenerated dura tissue.’ A second generation version of the ReDura is expected to receive its certificates in August of this year, and will be shipped all over the world soon afterwards.

Meanwhile, MEDPRIN is also looking at a large number of other human tissue products, including a personalized skull and maxillofacial repair system, a female pelvic diaphragm repair system, a tensionless urethral sling, a hernia repair piece, and artificial skin, blood vessels and ligament, many of which rely on the exact same 3D printing technique. In short, they are laying the technical foundations necessary for future development of more complex and advanced 3D printed artificial tissues and organs.

According to Xu Tao, the availability of 3D printed medical tissues could widely change over the coming years. ‘Tissue repair is a complex human organ regeneration process, and it has different requirements for different structures, ‘ he said. ‘The plan is to develop more than 10 kinds of implantable medical devices products within the next 5 years. Currently, we are leading the establishment of Guangzhou Research Institute of regenerative medical industry, seeking to integrate global and domestic regenerative medical technology and clinical resources to push 3D printing from biological tissue reconstruction all the way up to 3D printing of organ regeneration.’ In short, the 3D bioprinting revolution is definitely on its way, and Chinese scientists can be found at its forefront.

3ders.org - MEDPRIN 3D prints world’s first biological meningioma ReDura for use in brain surgery | 3D Printer News & 3D Printing News

 

[TaiShang]

A lot of "first in the world", these days

At this rate, cyborgs will emerge in China very soon. lol

 

[cnleio]

Also displayed at the expo is the hyperboloid cockpit window frames for the C919 aircraft, also made using the laser 3D printing technology. Some information about these crucial components was already unveiled at a workshop given by aviation materials specialist Professor Wang Huaming (Beijing University of Aeronautics and Astronautics) at the Chinese Academy of Sciences some months ago. He revealed that Chinese scientists now only needed just 55 days to 3D print four of these hyperboloid cockpit window frames for the C919.

That timeframe is especially impressive when compared to European manufacturers, who would need at least two years to do the same, with the mold alone costing $2 million USD. ‘The traditional aircraft manufacturing industry doesn't only need much more time, but also wastes too many expensive materials,’ Wang argued. ‘Normally, just 10 per cent of raw materials would be utilised, with the rest all cut and dropped during the processes of casting moulds, forging, cutting and polishing.’

That argument was further supported with an example from Lockheed Martin Aeonotics, who needed 2,796kg of titanium alloy to produce an F-22 fighter jet. According to Wang, only 144kg of the material was actually present on the plane itself. Wang has been studying 3D printable materials since 2000 with a team of researchers, and he further revealed that they reached the stage of mixing many different materials to imitate sophisticated, high-end components.

He firmly believes, he says, that 3D printing technology could help the Chinese government to overcome a long-standing technological bottleneck in the aviation industry. 'For me and many Chinese aircraft engineers, we all dream of 'printing out' all kinds of plane components we need one day,’ he said. One of the first results of that process are these huge titanium alloy structures as big as 5 square meters on display at the convention. It suggests that we can look forward to a lot more high-tech military applications in the near future.

3ders.org - China showcases large 3D printed metal frames for new generation of military aircraft | 3D Printer News & 3D Printing News

Chinese stealth fighter had done, with 3D printed tech help no any problem to mass production in next year.