Patient-Specific Implants & Anatomical Models
The loss of complex or extensive bone structures due to an accident or tumor creates
significant physical and emotional stress for patients. It also represents a great challenge
for the physician pondering the question of how the defect can be covered in the best
possible way.
The perfect implant for any situation
In such cases, patient-specific implants can be an effective means of mastering these
difficulties and keeping the resulting uncertainties under control.
Standard implants can deliver only less-than-satisfactory results in cases of severe
injuries or conditions caused by tumors. KLS Martin offers the perfect solution here:
Based on individual patient data, we create customized, perfectly fitting implants that
meet your needs both functionally and aesthetically. Extensive bone grafts are thus no
longer required.
The right material for each individual case
Ti - Additive manufacturing
PEEK - Polyetheretherketone
Ti - Solid titanium
Ti – Titanium mesh
Apart from highly advanced implant materials, we offer you top-notch 3D printing
technology that opens up completely new possibilities of designing your implants and
their surfaces!
Our comprehensive manufacturing facilities allow any type of processing.
Legende:
Patient-specific implants – Which base material for which purpose?
AM titanium
Subsequent implant correction
Mechanical strength
Biocompatibility
Thermal conductivity
Price level
Osseous integration potential
Volume reconstruction
Artifact likelihood
PEEK
Titanium mesh
Solid titanium
Implement your own project!
Our comprehensive range of services is many-faceted. Visit our dedicated webpage to
learn more about our anatomical models, implants and materials.
This direct access enables you to implement your own project in close collaboration with
us. Step by step: from your initial request to data upload.
> To learn more
Additive manufacturing (AM) – Opens up completely new
possibilities of implant and implant surface design!
How it works
Additive manufacturing refers to a 3D printing process in the field of generative
manufacturing methods. Inside a high-pressure chamber, titanium powder is delivered to
the working area using a doctor blade or roller. The titanium powder is then heated up by
a mirror-reflected laser beam, causing the powder to melt (which is why the method is
also called “laser melting”) and densifying the material as a result. Once the laser has
worked over the whole surface, the working platform (table) is lowered and a new layer
of titanium powder is applied on top. In this way, the workpiece is manufactured by
“adding” layer after layer. Since the power density of the laser used is extremely high, it
is possible to create high-density, three-dimensional objects.
AM method
Selective laser melting
What are the resulting user benefits?
Basically, the main advantages of additive manufacturing can be summarized as follows:
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Fast: No additional tools, jigs and fixtures are needed any more
Versatile: Free design of implants and implant surfaces
Osteoconductive: Implants with an open structure allow the ingrowth of endogenous cell
structures
Complex forms such as honeycomb, grid/lattice or porous structures are possible
High-strength: The density and thus the strength of the material will be higher compared
to a product made of pure titanium
Comprehensive and versatile – the manufacturing technology of
the KLS Martin Group
Our service portfolio
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Complete design work
Use of your datasets and joint discussion of potential problem solutions (e.g. by
online meeting) without any obligation on your part
Three-dimensional virtual representation of the defect reconstruction solution
Conventional manufacturing techniques (milling, turning, deep-drawing, machining,
etc.)
Resorbable materials (using cleanroom technology)
Anatomical models
Generative manufacturing methods (laser melting and laser sintering)
Quality assurance and validated processes
Advice by qualified sales persons without any obligation on your part
Indications
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Posttraumatic reconstructions
Loss of osseous integrity
Head injuries with increase of intracranial pressure
Tumors, ulcers, cysts
Infections or rejection responses following cranioplasty
Limited supply of autogenous bone grafts
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Additive manufacturing offers hospitals and physicians completely new possibilities for
creating patient-specific and therefore perfectly fitting implants in a very short time. The
treatment of orbital floor fractures, in which the KLS Martin Group is capable of delivering
the required implant within five to ten workdays, based on close collaboration with
customers, is just an example. Such short time frames were previously impossible, due
to the complexity of conventional process chains, not to speak of the superior quality of
accurately fitting implants and the planning safety assured by this new method.
Our generatively or “additively” manufactured implants close this gap, thanks to a fully
CAD-based design process directly followed by an integrated manufacturing process.
Important design features such as rounded, atraumatic edges can be additionally
implemented as you go, and the same applies to the insertion vector or a measuring
scale.
In this way, the implant is designed and manufactured according to the needs and
requirements of the indication so accurately that it almost falls into place when used.
Deviations from preoperative planning, malposition or interference with surrounding
tissues are therefore not to be expected.
Additional advantages of the implant include its high rigidity and load-bearing capacity.
And it won’t bounce either.
Arrangement of various defects
Before and during the operation
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No need for autologous bone grafts, no second surgical site for harvesting
Significantly shortened operating times
Lower rate of complications
Minimally invasive – high-precision intervention that preserves surrounding tissue
structures
After the operation
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Perfect mechanical protection for the brain
Low risk of rejection responses
Faster rehabilitation
Original appearance restored
Improved quality of life
For the public health system
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Solution for previously untreated or insufficiently treated patients
Significantly shortened operating times
Lower rate of complications
Shorter hospitalization
Lower overall treatment costs
Faster rehabilitation
Integrated case planning
Complex reconstruction cases traditionally involve a great number of variables that are
hard to control. UNIQOS utilizes the significant technical progress made in recent years in
the field of EDP-based preoperative planning, integrating these concepts and objectives
into an overall package that allows you to master even critical surgical situations.
From anatomical models and resection and positioning templates all the way to optimized
implants exactly adapted to individual patient requirements – the surgical team can now
use all the tools needed for successfully implementing the preplanned results.
Case example
By way of example, we’d like to describe here a case of mandibular reconstruction using
a fibula graft.
First of all, the resection limits are determined in a joint coordination process.
According to the decision of the team of treating physicians, the defect is to be
reconstructed with a fibular graft from the right leg.
As agreed, the right fibula is examined to locate the best possible matching graft.
A resection template is created, taking anatomical aspects into account.
The donor site is virtually projected to the recipient site and the graft ...
... is then optimized for best possible aesthetic results and prosthetic fit.
Finally, an implant specifically optimized for the given case is generated.
The entire service package at a glance.
To perform the resection as planned, resection templates are needed that also reflect the
cutting angle.
The final step involves defining the type, diameter and length of the osteosynthesis
screws to be used.