Medical Design Briefs - October 2023 - 47

Reshaping Medical Instrument Manufacturing with
New Technology
AFT outperforms
traditional subtractive
manufacturing and
machined metal
components.
9T Labs
Lowell, MA
Medical and surgical instruments
are utilized daily to save and improve
lives. Because of this, they demand an
exact level of accuracy and infallibility
in their manufacture. Traditionally, aluminum
and other metals have been the
standard material of choice for medical
and surgical instruments due to
their weight, strength, durability, and
cost benefits. However, new advances
in technology are challenging the
status quo and offering exciting new
manufacturing possibilities that allow
for greater material choices. One such
advancement already making waves in
the aerospace, leisure, and automotive
industries - and poised to benefit medical
and surgical manufacturing - is
Additive Fusion Technology (AFT)™.
n Additive Fusion Technology: What
Is It?
AFT, developed by Switzerland-based
9T Labs, is ushering in a new and
emerging standard in hybrid manufacturing
for continuous fiber composites.
This unique, automated technology
outperforms traditional subtractive
manufacturing and machined metal
components on cost, weight, performance,
and sustainability. The platform
leverages state-of-the-art integrated
software, high-precision additive manufacturing
processes, and advanced postprocessing
to deliver a seamless, threestep
solution.
* First, the software imports computeraided
design (CAD) files for templates
while optimizing structural
calculations.
This means the right amount
of material is placed right where it is
needed every time.
* Second, the software feeds this information
into a layup/preform machine
called a Build Module. The machine's
open material platform begins an adMedical
Design Briefs, October 2023
Neat PEKK
Continuous
CF/PEKK filament
Final stack-up
AFT™ can utilize materials such as polyetherketoneketone
(PEKK) that enable radiolucency
for accurate x-ray checks. (Credit: 9T Labs)
ditive manufacturing process using two
material deposition guides that place
thermoplastic filaments (e.g., PEKK,
PEI, and PEEK) next to unidirectional
(UD) continuous fiber-reinforced
tapes (e.g., carbon).
* Third, a compact compression press
fitted with matched-metal dies called a
Fusion Module uses heat and pressure
to fuse the preform parts and shape
them into final parts (with 100 percent
traceability and a fiber volume ratio
of up to 60 percent in a mold). The
process allows for a low void content
(< 1 percent), maximum interlaminar
strength, metal parts integration, and
reshaping.
n Benefiting Medical and Surgical
Instrument Manufacturing
AFT opens new possibilities for continuous
fiber performance when dealing
with very intricate and structurally loaded
components like the myriad medical
and surgical devices that modern, medicine
depends upon. This cutting-edge
technology can deliver the quick and
www.medicaldesignbriefs.com
Using materials such as polyether ketoneketone
(PEKK) enable parts to have dimensional stability after
repeated sterilization as well as being biocompatible.
(Credit: 9T Labs)
efficient production of small, strong
parts that are not only competitive on
cost compared to traditional metal parts,
but also represent a new standard for
sustainability. For example, it provides
a zero-waste benchmark, allows for the
manufacture of parts that are resistant
to repeated sterilization, and enables the
use of materials that can offer end-of-life
recycling opportunities without compromising
on the mechanical properties of
the material.
Additionally, AFT can utilize materials
such as polyetherketoneketone
(PEKK) that enable radiolucency for
accurate x-ray checks, have dimensional
stability after repeated sterilization, are
biocompatible (since they have shortterm
contact with the body), and offer
low mass for lower fatigue and greater
positioning accuracy.
n Case Study: Surgical Aiming Arm
Surgical aiming arms are used to align
surgical tools, pins, and bolts with holes
in a bone plate to repair shattered bones
47
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Medical Design Briefs - October 2023

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