Healthcare & Medical
DyeMansion bereitet den Weg für neue Materialien im Pulverbett 3D-Druck
3D-Druck Podcast: Post-Processing – Der Gamechanger für die Additive Fertigung
VaporFuse Surfacing, eine grüne Lösung für verbesserte Eigenschaften von Bauteilen
CERTIFIED SOLUTIONS FOR HEALTHCARE COMPANIES TO MEET PATIENT INDIVIDUAL REQUIREMENTS
ORTHOTICS
CASE STUDY: NOWECOR
Addressing complex surfacing challenges for high-demand orthopedic applications.
©DyeMansion, NOWECOR
©DyeMansion, NOWECOR
©DyeMansion, NOWECOR
Due to its material properties, Nowecor uses PA12 as it is an exceptionally suitable material for various orthopedic applications on the human body. However, the specific needs of patients demand a specialized finish, particularly concerning haptics and color, as well as enhanced mechanical properties, such as sweat resistance and hygienic cleanability.
The VaporFuse Surfacing process provides PA12 parts with a glossy, smooth and sealed surface. The part’s geometry is preserved, which is crucial for medical applications while skin feel is enhanced, and flexibility slightly increased. This treatment makes components sweat-resistant and hygienically cleanable. When combined with the DM60, it offers a nearly unlimited spectrum of colors, from bright and vibrant hues to custom skin tones.
- Sealed surfaces with preserved geometry
- Enhanced flexibility
- Pleasant haptics for skin contact
- Sweat-resistant and easily hygienically cleanable
- Available in a wide range of vibrant colors or custom skin tones
Dental Sleep Appliance
CASE STUDY: GOODSLEEP CO
The Hushd Pro Avera is a fully 3D-printed, patient-specific intraoral device designed to treat sleep-related breathing disorders such as snoring and sleep apnea.
©DyeMansion, GOODSLEEP CO
Before adopting additive manufacturing, Good Sleep Co faced limitations in producing the Hushd Pro Avera with consistent quality and full patient-specific customization. Conventional manufacturing methods restricted design freedom and made it difficult to achieve precise anatomical fit. Surface quality and hygiene were critical, as rough or porous surfaces can impact comfort, cleanliness, and regulatory compliance. Manual finishing processes were time-consuming, inconsistent, and hard to validate for medical use. A reliable surface treatment was therefore the key requirement for making 3D printing a viable production method.
Good Sleep Co implemented VaporFuse Surfacing using the DyeMansion VXI to meet the highest medical and aesthetic standards. The process creates a smooth, sealed surface that significantly improves comfort, hygiene, and visual quality. DyeMansion’s VaporFuse Eco Solvent for the VX1 is FDA GRAS-listed (21 CFR 184.1666) as processing aid making it suitable for long-term intraoral applications. The automated process ensures consistent, repeatable results across all parts. This enabled Good Sleep Co to confidently transition to 3D printing for medical device production.
Today, the Hushd Pro Avera is fully 3D-printed and individually customized for each patient. Complex geometries and personalized designs can be produced quickly through a fully digital workflow. The smoothed surfaces deliver a premium look and feel while improving durability and ease of cleaning. Manual post-processing has been significantly reduced, increasing efficiency and scalability. As a result, Good Sleep Co can now deliver high-quality, patient-specific oral appliances on a scale.
VX1
“With DyeMansion’s VXI vapor smoothing technology, we were able to elevate the quality, hygiene, and scalability of our Hushd Pro devices to a truly production-ready medical standard.”
ORTHOTICS
Case Study: HKK Bionics
Patient-individual hand orthosis with integrated sensors to restore the gripping function of paralyzed hands
©DyeMansion, HKK Bionics
The final product consists of many different small parts that all need to be assembled. All those parts require a homogeneous surface treatment and consistent coloring. In the end a medical product like this must pass tests for cytotoxicity and skin irritation tests, which sets high demands to all processes involved. Since the product is worn by patients every day, it must look and feel good.
Homogeneous surfaces with pleasant haptics and matching skin colors: To produce the 3D-printed parts of the exomotion hand one, HKK Bionics works in cooperation with German 3D-printing service bureau Teufel Prototypen and DyeMansion to deliver the right surface treatment and individual colors for their orthotics. Every orthotic is unique and customized.
Passed tests for cytotoxicity and skin irritation according to ISO norms and furthermore:
- matching skin tones
- improved & homogeneous haptics
- reproducible results for all the small parts being assembled to one orthotic
POLYSHOT CLEANING
POLYSHOT SURFACING
DEEPDYE COLORING
“With DyeMansion technology we are able to deliver finished and colored products that can be used in everyday life. The developed skin tones can help patients to identify with their orthosis and to accept it as an aid in everyday life. In addition, the existing certificates for cytotoxicity and skin irritation help us to pass relevant certifications and tests with the exomotion hand one.”
ORTHOTICS
Case Study: Pohlig
3D-printed customized orthotics for kids with integrated accessories
©Pohlig
PROSTHETICS
Case study: Quorum Prosthetics
The Quatro is an award-winning patented prosthetic that gives users the ability to adjust the volume and compression of the device
©Quorum Prosthetics
Quorum Prosthetics has been making custom prosthetics for almost 24 years now and got into Additive Manufacturing in 2020. Raw printed MJF parts are abrasive when coming out of the printer, making it tough for patients to wear prosthetics that have not been finished.
The material, Evonik’s INFINAM ®* TPA 4006 P, is characterized by abrasion resistance and high mechanical properties which tend to complicate traditional vapor polishing. DyeMansion was able to create a new program for the Powerfuse S – designed specifically for this TPA to ensure a high level of smoothing that has not been achieved before with TPA.
Having it smoothed enables the patient to get in the prosthesis more easily and you even can achieve vacuum with a small part, which is quite important. Furthermore, it strengthens it too and makes it more comfortable for the patient to wear on a daily basis.
POLYSHOT CLEANING
VaporFuse Surfacing
PROSTHETICS
Case study: Gottinger
3D-printed leg Prosthetics
©DyeMansion, Gottinger
Gottinger Handelshaus OHG has been at the forefront of orthopedic technology since 1901. In 2012 it made Additive Manufacturing a core part of its technological skillset. To bring a 3D-printed medical product on the market meant that a lot of hurdles needed to be overcome. The request for a specific skin tone came from a patient.
Gottinger has successfully certified its SLS leg protheses according to the DIN EN ISO 10328: 2007 standard. Here, force, rotation, and resistance are tested. For this standard, 2,000,000 steps were simulated, which the prosthetic foot survived unscathed.
With DyeMansion, Gottinger found a reliable partner to fulfill their needs when it comes to a pleasant finish of their prosthetics. Together we were even able to dye the leg prosthetic in the patient’s skin color. For those patients who do not require skin tones, Gottinger is able to offer a wide array of different colors.
POLYSHOT CLEANING
PolyShot Surfacing
DEEPDYE COLORING
SURGERY GUIDES
Case study: Avsar
3D-printed surgery guide
©Avsar
To create an exact surgical guide for patients that met biocompatibility standards and could be produced in a short amount of time. The surgical guides are used to show patients what outcome to expect from their reconstructive surgery (for example after a disconfiguring injury).
The use of 3D-printing along with DyeMansion post-processing technology allowed Avsar to exactly replicate the patient’s anatomy and skin-tone for each part. This could only be achieved due to the ability to print and finish complex objects and shapes that would otherwise not be possible to create through any conventional methods.
Avsar is able to create customized products fitted to each patient’s needs in a much shorter time than would be required with conventional manufacturing methods. The process is also very cost-effective, as there is no need to store large amounts of goods or materials.
POLYSHOT CLEANING
PolyShot Surfacing
DEEPDYE COLORING
Color is true freedom of design
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