1. 3D-CAD
The component to be produced is designed three-dimensionally on the PC and forms the starting point for production.
C-Fit 3D®
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You can find further information on the planning process, as well as interesting examples of custom-made products in our flyer.
Overview
Process
Creation process of a custom-made product
Made to measure
Precise planning is the basic prerequisite for a perfectly fitting implant. It is just as important that the production is accurate to size in order to implement the previous planning exactly. For this reason, we use additive manufacturing (3D printing) as the method of choice in most cases.
Additive manufacturing enables the production of implants with an EPORE® surface. On request, individual implants can be provided with an EPORE® surface and various coatings.
The production time for a customized prosthesis is between 2 and 9 weeks, depending on the scope of production.
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.
Creation process of a custom-made product
Case studies
Over 20 cases in the new
C-Fit 3D® app
Custom-made products from the shoulder to the ankle.
- Detailed case description
- 3D view
- Real treatment examples
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Case study
MUTARS® diaphyseal implant femur
10-year-old patient with a Ewing sarcoma in the right diaphyseal femur. A proximal resection was planned just below the growth plate on the greater trochanter in order to preserve it as far as possible. The planned resection is shown.
Planned prosthesis system
A prosthesis system was planned with a custom-made proximal and distal component in combination with a MUTARS® arthrodesis implant which, in contrast to the classic MUTARS® connecting part for diaphyseal implant, replicates the curvature of the femur. The proximal component has a bulge with a hole for fixing the iliopsoas tendon and a hole for fixing the greater trochanter. Due to the large resection, a custom-made hollow stem with an oval design was planned for the distal end.
Prosthesis position
The precise positioning of the prosthesis components ensures optimal functionality and adaptation to the patient's anatomical conditions. This is crucial for the long-term success of the implantation.
Resection and preparation
A patient-specific resection guide was prepared for the resection of the proximal femur. Drill guides for the proximal and distal femur and a trial implant were also provided.
Postoperative result
The surgeon was satisfied with the result. The postoperative X-ray images show the proximal (left) and distal (right) components as well as the MUTARS® arthrodesis implant (center).
Growth prostheses
Growth prostheses
Non-invasive limb lengthening
MUTARS® Xpand
- Specially developed for the treatment of tumors in children and young adults
- Designed for limb preservation and compensation of arm and leg length differences
- Integrated motor for lengthening up to 100 mm
- No additional risk of infection during the lengthening process thanks to non-invasive prosthesis lengthening (can be performed at home)
- Lengthening in small increments (0.035 mm per impulse) to protect soft tissue and nerves
MUTARS® BioXpand
- Specially developed for the treatment of tumors in children and young adults
- Designed for limb preservation and compensation of arm and leg length discrepancies
- Integrated FITBONE® intramedullary nail for lengthening up to 80 mm
- No additional risk of infection during the lengthening process thanks to non-invasive prosthesis lengthening (can be performed at home)
- Lengthening in small increments (0.035 mm per impulse) to protect soft tissue and nerves
- Creates bone length by means of callus distraction
- The demanding surgical technique requires special user training in advance