1. 3D-CAD
The component to be produced is designed three-dimensionally on the PC and forms the starting point for production.
Overview technology
Production
Investment casting
Using the lost wax process, we produce 300,000 high-precision and complex investment casting components every year with the aid of robots. After casting, these are subsequently heat-treated and then tested using X-rays.
By tearing test specimens and metallographically examining the microstructure, we ensure that our implants more than meet all national and international standards.
Machining
More than 100 employees work on over 50 state-of-the-art CNC machines, some of which are fully automated, to produce 230,000 high-precision implants made of titanium, CoCrMo, and stainless steel alloys, as well as polyethylene, every year.
Quality assurance
Quality assurance is an important part of implantcast. More than 40 colleagues ensure that all standards, drawings and other specifications are adhered to. They check more than 820,000 products every year, from manual measurement to fully automated 3D coordinate measurement.
Additive manufacturing
The existing manufacturing processes are complemented by additive manufacturing. This process is one of the most innovative technologies of the beginning century. It allows the production of extremely complex structures and geometries that cannot be realized with conventional manufacturing processes.
Finish
In the finish department, our implants and instruments are brought to their final state to fully meet the specifications of the drawings. Highly specialized employees take care of the process, which is still done largely by hand, since machines cannot always replace people, especially when it comes to polishing.
Research and development
Innovation for health
A look behind the scenes of our R&D department
Research & Development (R&D) is at the heart of our innovations. This is where interdisciplinary and international teams of engineers, doctors and scientists work to shape the medical technology of tomorrow.
From the initial idea and prototypes to market readiness - we develop new technologies that have the potential to improve lives. Our goal is to advance medical progress, be it by developing state-of-the-art, minimally invasive instruments or complex implants. Together, we are setting new standards in medical technology.
What drives us?
- Improving patient safety and comfort
- Making medical technology solutions more efficient
- Creating innovations for sustainable healthcare
Quality management
Quality at implantcast
Our quality management system regulates and ensures the processes at implantcast GmbH through clear specifications. This process begins with the development of new products or the selection of raw materials, it continues through all production processes and ranges up to the final inspection of finished products and logistical processes such as the dispatch of goods to our customers. The quality management system thus ensures consistently high quality at all stages of the process and for every product.
Thanks to these quality efforts, implantcast GmbH is able to fulfill both national and international requirements for a quality management system. This is regularly confirmed by audits by our notified body and international authorities.
Additive manufacturing
Next-generation implants through additive manufacturing
Conventional manufacturing processes such as investment casting and machining have been complemented by additive manufacturing at implantcast since 2014. Additive manufacturing is one of the most innovative technologies of the early 21st century. It allows the production of extremely complex structures and geometries that are difficult or impossible to realize with conventional production methods. This includes the production of implants that are precisely tailored to the anatomy of the patient. The use of this technology significantly accelerates production time, especially for individual prostheses, while at the same time offering a high degree of design freedom and allowing the production of structures with a high degree of primary and secondary fixation in the bone.
Additive manufacturing process - EBM® (electron-beam melting)
Digital 3D data (3D CAD) is first combined into production batches in the additive manufacturing department and prepared for production with the EBM systems using specialized software. For the subsequent production process, the process chamber is first placed under high vacuum. The structure/geometry of the implant components is then built up automatically by applying a layer of powder around 50 µm thick with the aid of an electron beam. Although the electron beam travels at up to 8,000 m/s, the production of a manufacturing batch can take several days.
Process chain of additive manufacturing
Additive manufacturing with the EBM® is a fully automated cyclical process.
2. slicen
The model is cut virtually on the PC into individual slices, each of which corresponds in height to the layer thickness of the additive manufacturing process.
3. powder application
In the first step, an even layer of powder is applied using a doctor blade system. The height of the powder layer corresponds to the layer thickness previously generated on the PC.
4. melting
The powder is exposed with a beam source along calculated paths and completely melted. The melt solidifies and fuses metallurgically with the underlying layer.
5. lowering
After a layer has been exposed, the working platform is lowered by the layer height. The process (steps 3-5) is repeated: A powder layer is applied and selectively exposed.
6. component removal
The component is removed. Unexposed powder is recycled and completely reused.
EPORE®
EPORE® is an additively manufactured, highly porous structure based on a titanium alloy (TiAl6V4). This material is particularly suitable for implant components because it is biologically inert and ductile, and has high corrosion resistance and fatigue strength.
EPORE® was developed to create a high porosity with a low modulus of elasticity. It is very similar to the structure of bone and thus promotes the ingrowth of the implant into the bone.
Mechanical properties in comparison
EPORE®
- Porosity: 61 ± 8 %
- Rod thickness: 360 ± 50 μm
- spec. modulus of elasticity: 3.1 ± 0.6 GPa
Cancellous bone
- Porosity 30-90%
- Trabecular diameter 0.1-0.2mm
- E-modulus 0.5-1.5 GPa