3D printing has faced a lot of scrutiny from the press over the past few months, with reports of people using the devices to print guns in their homes. This scaremongering is expected amongst new technologies, but people aren’t seeing the great ways that 3D printers are not only changing the way we look at production, but also changing lives across the world.
One of the stories that caught the attention of tabloids worldwide was that of baby Kaiba Gionfriddo, who was diagnosed with tracheobronchomalacia, a condition that makes his windpipe extremely weak, to the point of it collapsing, preventing air from flowing to his lungs.
Kaiba was rushed to hospital, was placed on a ventilator and had a tube inserted into his trachea to help him breathe, but the problems continued.
Researchers at the University of Michigan began working on a life-saving solution for Kaiba, a splint that would fit around his airway to hold it open and enable him to breathe easily, made entirely from a 3D printer.
Kaiba’s cast and model of a trachea.
Splints are usually made by hand, however they are not always an exact match for the airway and can take a long time to produce. Kaiba was the first patient to be treated using this new method.
CBR spoke exclusively to Dr. Glenn Green and biomedical engineer Scott Hollister, both of the University of Michigan, who designed and fitted the life-saving 3D printed splint.
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Scott Hollister, Ph.D. and Glenn Green, M.D.
Hollister explained the process of creating the splint using the 3D printer: "I first had written a software to automatically design the splint geometry (shape, bellow structure, suture holes, etc.) where the user can select a variety of parameters (including splint length, diameter, opening angle, suture hole spacing etc). From the custom software we create digital representations of the splint in surface .STL format. We then take the CT scan of the patient, import the digital splint designs, and virtually fit the design to the collapsed airway.
"We select a range of feasible designs and the send these designs in STL format to the EOS laser sintering software, which then slices then designs and prepares the input for the laser sintering system. We load up about ½ to 1 kilogram of the PCL powder into the machine, and set the parameters for the machine to build the parts. Once finished, the parts are removed for the powder bind, and cleaned using compressed air and sonication of the excess powder. They are sent out to be ethylene oxide sterilized and packaged, after which they are brought to the operating room."
Having worked on splint prototypes for several months, Hollister found that it was not too difficult to make Kaiba’s splint. He believes that 3D printing should be used more regularly in medical situations as "it allows the creation of patient specific and custom devices for tissue and eventually organ reconstruction". However he thinks that more research is needed on "how to adapt biomaterials to 3D printing technology". He even believes that these printers could one day reduce healthcare costs.
Dr. Glenn Green operated on Kaiba and said it the operation "went very smoothly due to extensive preparation and an elite surgical team".
When asked if he would like to see this kind of technology be used more often in medical cases, he said, "We developed this technology to treat a very tough medical problem. Children presently die or have substantial long-term invasive care. We hope to benefit the lives of many others".
Green was "pleased beyond expectation" with the results and believes that "we will see more and more applications over the coming decades. 3D printing offers elegant solutions to very problematic areas".
So what would the alternatives have been without the 3D printed splint? According to Green: nothing. "The operation would not have been possible without the splint. There was no other viable alternative."
Kaiba’s splint will dissolve after several years when he no longer needs it. He is now living his life like any other little boy.
Kaiba Gionfriddo is held by his mother April Gionfriddo. Photo taken in summer 2012.
Another 3D printing related story that has caught the eyes and heart of people everywhere is that of South Africa based company, Robohand. It is inspiring people worldwide to look at the way 3D printers can be utilised to change lives. The company builds prosthetic hands using 3D printers, and even puts instructions online for customers to make their own, as the cost of such operations and technologies are often incredibly expensive.
The company was founded by Richard Van As from South Africa and Ivan Owen from the US. Speaking to CBR, Van As described how the company has grown from prototypes and sleepless nights to a successful and helpful organisation, changing lives the world over.
"I had a wood working accident and cut off my fingers. When doing research, there are no functioning prosthetics for tradesmen so I decided to build my own."
"Everything was a challenge, but if you apply your mind and think outside the box, anything is possible."
When asked how he overcame these challenges and the constant glitches that are inevitable with such a complex new venture, he said it was "many sleepless nights of designing".
"The first few prototypes were for fingers only and were done using all sorts of materials. Eventually they were cnc machined in aluminium. 3D printing only came later as we realised the need for full hands for children that required a cheap alternative as they grow".
Using a MakerBot Replicator 2 3D printer, the team make prosthetic arms and hands to fit anyone who is in need of one, from babies to adults, with the ability for people to make their own prosthetic limbs using personal 3D printers if they have one available for use.
Van As continues: "The design is open source and available for download from Thingiverse.com. Anyone can print one and put it together. There is also a manual available for download with pictorial instructions. In each country the cost will vary due to purchasing of material".
But with such innovative technology, it never slows down. According to Van As, the company continues to expand: "Research and development does not sleep, so there are always new improvements being done to the designs. We are in the process of getting a USA clinic up and running".
"Young children and tradesmen who are able to go back to work after receiving a Robohand or Roboarm are my inspiration".
With prices of 3D printers gradually lowering, people are starting to see their potential. Who knows, maybe one day everyone will have their own 3D printer, and the possibilities for creation will be endless.
