Development of a smart scaffold design and design of individual replacement structures in the context of a continuous process chain
| Runtime | 01.11.2021 – 31.10.2023 |
| Overall project | Smart scaffold template system for precise NC-assisted shaping for individualized bone grafting |
| Acronym | Smaffold |
| Funding | BMWK (AiF ZIM) |
| Funding Reference | KK5366401BM1 |
| Project Lead | |
| Project Staff | Dipl.-Ing. Arthur Hilbig, Dr.-Ing. Philipp Sembdner, Dr.-Ing. Stefan Holtzhausen |
| Partners |
Organical CAD/CAM GmbH, Berlin |
| Technische Universität Dresden, Klinik und Poliklinik für Mund-, Kiefer- und Gesichtschirurgie |
Motivation
Dental diseases or certain traumas often lead to tooth loss, which is treated with artificial dentures. A dental implant is often used as a tooth replacement, which is attached in the place of the original tooth. If the implant is not placed immediately after tooth loss, the unused jawbone will reduce. However, to ensure a stable hold and ideal ingrowth of the implant, a certain amount of residual bone must be present. Therefore, bone replacement material is used to build up the bone (augmentation), for example. One possibility is the precise fabrication of individual replacement structures even before the operation itself. This involves virtual planning of the prosthetic restoration and subsequently of the necessary individual bone replacement. Previous work indicates a similar recurrent process along the reverse engineering process chain to develop and design a customized bone replacement structure for the patient based on image data in modeling. These individual replacement structures can then be manufactured additively. Calcium phosphate cement (CPC or bone cement), for example, is used as the material in this process. The use of bone cements in combination with additive manufacturing processes enables defined adaptation and control of the porosity of the lattice structure depending on patient-specific boundary conditions.
Objective
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The aim of the project is to separate the functionalization and shaping of the individual bone replacement structure for the patient-specific restoration of bone defects in the oral and maxillofacial region in terms of time and manufacturing technology in order to fully exploit the advantages of the respective manufacturing processes. This is to be achieved on the one hand by developing a smart scaffold template system (Smaffold-CPC-PreFab-System = product to be developed). The prefabricated functionalized scaffold templates (hereinafter also referred to as scaffold blanks) contained in this system are manufactured in advance at time t1 using additive manufacturing processes from resorbable bone substitute material (CPC) and are given their individual functional properties (porosity) in the process. On the other hand, the disadvantages of previous methods are to be countered by establishing a robust and fast subtractive CAD/CAM processing with an efficient and intuitive CAx process chain for the digital data and information flow (= method to be developed). At time t2, a suitable template for the patient case is selected from the PreFab system and the individual shaping is achieved by CAD/CAM milling. In addition to the manufacturing strategies, the focus of the development is on the optimization of conventional dental machine systems with regard to cooling and cleaning (hygiene). The overall objective is to establish cost-effective manufacturing concepts with high flow rates (market demand) and to prepare the overall process for a future ChairSide application for direct manufacturing of the individual bone replacement structures during a surgical procedure. |
Project content
- Process development with selection of an additive prefabricated functionalized scaffold template and precise subtractive milling for shaping.
- Product development: Smart CPC PreFab system with prefabricated functionalized scaffold blanks
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Product development: Individually shape-matched bone replacement structure
