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<p>Binder Jetting (BJT) is a promising, yet scarcely explored, additive manufacturing technology suitable for the production of orthopedic surgical instruments, offering design flexibility, material versatility, and cost-effectiveness compared to traditional subtractive manufacturing. This study assesses the feasibility of metal BJT for manufacturing surgical instruments used in knee and hip arthroplasty. Given the limited availability of literature data about such a technology, a preliminary evaluation of sample density, mechanical properties, and dimensional accuracy was performed, taking into account the main geometrical features characterizing surgical instruments. The results demonstrate that BJT enables the fabrication of lightweight and complex geometries while achieving satisfying mechanical properties. Thin walls (0.2&#xa0;mm), small holes (0.5&#xa0;mm), and cylindrical extrusions (0.7&#xa0;mm) were successfully printed, providing insights into BJT resolution limits. However, shrinkage during sintering was a significant challenge, requiring tailored sintering supports and counter-deformation strategies for dimensional and geometrical accuracy. The application of linear scaling factors partially mitigated anisotropic shrinkage, with deviations up to 0.44&#xa0;mm for prismatic samples. Mechanical properties varied with the z-level in the print chamber, limiting the repeatability of components' performance within the printing volume. In addition, lightweight designs for surgical instruments, such as trial acetabular cups and femoral stems, were successfully manufactured, achieving significant weight reduction while maintaining functional performance. The study identifies critical Design for Additive Manufacturing (DfAM) guidelines for metal BJT, emphasizing strategies to address sintering distortions. Despite challenges, BJT shows strong potential for producing customizable and lightweight surgical instruments, paving the way for its broader adoption in biomedical manufacturing.</p>

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Manufacturing of surgical instruments by Binder Jetting 3D printing: a feasibility study

  • 期刊论文

  • 发表日期：

    2025年7月24日

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  • Sara Candidori,
  • Lorenzo Cocchi,
  • Marco Mariani,
  • Massimiliano Bestetti,
  • Roberto Viganò,
  • Serena Graziosi,
  • Nora Lecis

摘要

Binder Jetting (BJT) is a promising, yet scarcely explored, additive manufacturing technology suitable for the production of orthopedic surgical instruments, offering design flexibility, material versatility, and cost-effectiveness compared to traditional subtractive manufacturing. This study assesses the feasibility of metal BJT for manufacturing surgical instruments used in knee and hip arthroplasty. Given the limited availability of literature data about such a technology, a preliminary evaluation of sample density, mechanical properties, and dimensional accuracy was performed, taking into account the main geometrical features characterizing surgical instruments. The results demonstrate that BJT enables the fabrication of lightweight and complex geometries while achieving satisfying mechanical properties. Thin walls (0.2 mm), small holes (0.5 mm), and cylindrical extrusions (0.7 mm) were successfully printed, providing insights into BJT resolution limits. However, shrinkage during sintering was a significant challenge, requiring tailored sintering supports and counter-deformation strategies for dimensional and geometrical accuracy. The application of linear scaling factors partially mitigated anisotropic shrinkage, with deviations up to 0.44 mm for prismatic samples. Mechanical properties varied with the z-level in the print chamber, limiting the repeatability of components' performance within the printing volume. In addition, lightweight designs for surgical instruments, such as trial acetabular cups and femoral stems, were successfully manufactured, achieving significant weight reduction while maintaining functional performance. The study identifies critical Design for Additive Manufacturing (DfAM) guidelines for metal BJT, emphasizing strategies to address sintering distortions. Despite challenges, BJT shows strong potential for producing customizable and lightweight surgical instruments, paving the way for its broader adoption in biomedical manufacturing.