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EP3110363A1 - Method for producing a medical instrument by way of an additive method - Google Patents

Method for producing a medical instrument by way of an additive method

Info

Publication number
EP3110363A1
EP3110363A1 EP15702693.1A EP15702693A EP3110363A1 EP 3110363 A1 EP3110363 A1 EP 3110363A1 EP 15702693 A EP15702693 A EP 15702693A EP 3110363 A1 EP3110363 A1 EP 3110363A1
Authority
EP
European Patent Office
Prior art keywords
instrument
additive
head
medical instrument
production
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP15702693.1A
Other languages
German (de)
French (fr)
Inventor
Karl-Heinz Danger
Michael Küllmer
Frank Hagemann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gebrueder Brasseler GmbH and Co KG
Original Assignee
Gebrueder Brasseler GmbH and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gebrueder Brasseler GmbH and Co KG filed Critical Gebrueder Brasseler GmbH and Co KG
Publication of EP3110363A1 publication Critical patent/EP3110363A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C3/00—Dental tools or instruments
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B17/16—Instruments for performing osteoclasis; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/1615—Drill bits, i.e. rotating tools extending from a handpiece to contact the worked material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C3/00—Dental tools or instruments
    • A61C3/02—Tooth drilling or cutting instruments; Instruments acting like a sandblast machine
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C3/00—Dental tools or instruments
    • A61C3/02—Tooth drilling or cutting instruments; Instruments acting like a sandblast machine
    • A61C3/03—Instruments operated by vibration
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C3/00—Dental tools or instruments
    • A61C3/06—Tooth grinding or polishing discs; Holders therefor
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C3/00—Dental tools or instruments
    • A61C3/12—Tooth saws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D65/00—Making tools for sawing machines or sawing devices for use in cutting any kind of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/362—Laser etching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
    • B23P15/32—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools twist-drills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
    • B23P15/34—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools milling cutters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B2017/00526—Methods of manufacturing
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods
    • A61B17/16—Instruments for performing osteoclasis; Drills or chisels for bones; Trepans
    • A61B2017/1602—Mills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • Medical instruments such as dental drills, milling cutters, grinding instruments, sonic tips or saw blades are conventionally machined in accordance with the prior art. This is usually based on a semi-finished, which is machined in different steps. In particular, the production of cutting or toothing takes place by milling or grinding.
  • the invention has for its object to provide a method for producing a medical instrument, which avoids the disadvantages of the prior art and allows a precise and cost-effective production.
  • the object is achieved by the combination of features of claim 1, the dependent claims show further advantageous embodiments of the invention.
  • the medical instrument is produced by means of an additive manufacturing method.
  • this additive manufacturing method can be used either for the entire instrument or for a part thereof, for example for a head provided with cutting edges.
  • the medical instruments in question are essentially very small components (in particular dental drills or dental cutters).
  • the amount of additive to be applied material is thus low. This results in the possibility to enable a very fast and therefore very cost-effective production of high volumes.
  • the manufacturing method according to the invention is suitable both for the individual production of a single instrument, as well as for the simultaneous production of a plurality of instruments in a common device for additive manufacturing.
  • the additive or generative production method to be used according to the invention thus provides for the direct structuring of a medical instrument in a layered manner and across layers. It is particularly advantageous if the instrument is manufactured in a vertical arrangement. This makes it possible in particular for rotating instruments to produce these rotationally symmetrical to a rotation axis, so that no reworking are required. Furthermore, the training of support regions which would have to be subsequently removed again in a vertical arrangement, ve réelleet we rd s ⁇
  • the additive production according to the invention is preferably carried out using a powder material or the like.
  • the instrument is built up layer by layer in a container filled with the powder.
  • the respective upper powder layer is produced by selective laser melting, selective laser sintering, electron beam deposition welding or a DLD process. Subsequently, the next powder layer is applied, wherein the powder is accurate to produce the instrument by means of the laser or electron beam or otherwise melted and solidified.
  • Usual layer thicknesses are between 20 pm and 100 ⁇ .
  • the additive manufacturing processes allow the production of medical instruments whose mechanical properties largely correspond to those of the base material used. This results in large component densities, which can be almost 100%. It follows that the instruments according to the invention have a high strength and thus have both a long life and a good cutting performance.
  • the medical instrument is produced in a mixed construction or hybrid construction.
  • This solution variant can prove to be particularly advantageous when the machining of a tool in the region of its shaft and its clamping area can be automated and only the production of the head can be made in a single additive manufacturing step.
  • the method according to the invention is also suitable for reworking additively produced areas of the medical instrument by means of a removing method. For example, it is possible to sharpen or calibrate the cutting edges, for example a head of a milling cutter, by means of a laser ablation process. This can also be done, for example, to improve the concentricity of a rotating medical instrument.
  • a removing method For example, it is possible to sharpen or calibrate the cutting edges, for example a head of a milling cutter, by means of a laser ablation process. This can also be done, for example, to improve the concentricity of a rotating medical instrument.
  • FIG. 1 shows a schematic side view of a semi-finished product to be used
  • FIG. 2 shows a production step with the production of a shank
  • FIG. 3 shows a ready-made additive medical instrument in the form of a drill or milling cutter
  • Fig. 4 is a micrograph of the typical structure of drawn steel followed by heat treatment
  • 5 is a micrograph of a material produced by an additive laser reflow process.
  • Fig. 1 shows as a starting material for a combined manufacturing process, a semi-finished product 1, which is in the form of a cylindrical pin or wire.
  • the semifinished product is machined to produce a shaft 2 with a clamping area 3 and a neck 4.
  • This intermediate product is then finished by means of an additive process by applying layered material to produce a trimmed head 5.
  • a sharpening of the cutting by means of a removing process for example, a laser ablation process, take place.
  • FIGS. 4 and 5 are micrographs showing a comparison between a conventionally produced material and a material produced by an additive method.
  • the grinding pattern shown in FIG. 4 is a conventionally produced material which has the typical structure of a drawn steel with subsequent heat treatment.
  • the longitudinal carbides in the martensitic matrix are clearly visible.
  • FIG. 5 shows a grinding of a material produced by means of an additive laser reflow process.
  • a coarse, martensitic microstructure with fine carbide precipitations can be clearly seen, which have no special arrangement. It proves to be advantageous in additively produced workpieces that they do not form any hardening cracks, as is the case with conventionally produced workpieces.

Landscapes

  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Veterinary Medicine (AREA)
  • General Health & Medical Sciences (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Dentistry (AREA)
  • Public Health (AREA)
  • Animal Behavior & Ethology (AREA)
  • Physics & Mathematics (AREA)
  • Epidemiology (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Surgery (AREA)
  • Medical Informatics (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Nuclear Medicine, Radiotherapy & Molecular Imaging (AREA)
  • Molecular Biology (AREA)
  • Orthopedic Medicine & Surgery (AREA)
  • Ceramic Engineering (AREA)
  • Dental Tools And Instruments Or Auxiliary Dental Instruments (AREA)
  • Laser Beam Processing (AREA)
  • Materials For Medical Uses (AREA)
  • Dental Prosthetics (AREA)
  • Powder Metallurgy (AREA)

Abstract

The invention relates to a method for producing a medical instrument, characterized in that said instrument is at least partly produced by way of an additive production method.

Description

Verfahren zur Herstellung eines medizinischen Instruments mittels eines additiven Verfahrens  Method for producing a medical instrument by means of an additive method

Beschreibung  description

Medizinische Instrumente, wie beispielsweise Zahnbohrer, Fräser, Schleifinstrumente, Schallspitzen oder Sägeblätter werden gemäß dem Stand der Technik in klassischer Weise spanend hergestellt. Dabei wird üblicherweise von einem Halbzeug ausgegangen, welches in unterschiedlichen Arbeitsschritten spanend bearbeitet wird. Insbesondere die Herstellung von Schneiden oder Verzahnungen erfolgt dabei durch Fräsen oder Schleifen. Medical instruments such as dental drills, milling cutters, grinding instruments, sonic tips or saw blades are conventionally machined in accordance with the prior art. This is usually based on a semi-finished, which is machined in different steps. In particular, the production of cutting or toothing takes place by milling or grinding.

Die klassischen Herstellungsverfahren weisen den Nachteil auf, dass sie nur für bestimmte Geometrien geeignet sind. So ist es beispielsweise nicht möglich, Hinterschnitte oder Hohlräume herzustellen, da die Geometrie des Instruments in direkter Beziehung steht zu den Herstellungsverfahren und den verwendeten Werkzeugen. The classical production methods have the disadvantage that they are only suitable for certain geometries. For example, it is not possible to make undercuts or cavities because the geometry of the instrument is directly related to the manufacturing processes and tools used.

Die Entwicklung derartiger Instrumente ist somit in gewissem Maße durch die zur Verfügung stehenden Herstellungsverfahren limitiert. The development of such instruments is thus limited to some extent by the production methods available.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Herstellung eines medizinischen Instruments zu schaffen, welches die Nachteile des Standes der Technik vermeidet und eine präzise und kostengünstige Herstellung ermöglicht. The invention has for its object to provide a method for producing a medical instrument, which avoids the disadvantages of the prior art and allows a precise and cost-effective production.

Erfindungsgemäß wird die Aufgabe durch die Merkmalskombination des Anspruchs 1 gelöst, die Unteransprüche zeigen weitere vorteilhafte Ausgestaltungen der Erfindung. Erfindungsgemäß ist somit vorgesehen, dass das medizinische Instrument mittels eines additiven Herstellungsverfahrens hergestellt wird. Dieses additive Herstellungsverfahren kann erfindungsgemäß entweder für das gesamte Instrument oder für einen Teil desselben, beispielsweise für einen mit Schneiden versehenen Kopf, verwendet werden. According to the invention the object is achieved by the combination of features of claim 1, the dependent claims show further advantageous embodiments of the invention. According to the invention, it is thus provided that the medical instrument is produced by means of an additive manufacturing method. According to the invention, this additive manufacturing method can be used either for the entire instrument or for a part thereof, for example for a head provided with cutting edges.

Bei den additiven Herstellungsverfahren, welche die Fertigung von medizinischen Instrumenten, beispielsweise aus Stahl, Keramik, Hartmetall, Titan oder Kunststoff ermöglichen, wird üblicherweise von einem pulverförmigen Material ausgegangen. Dieses wird schichtweise aufgeschmolzen, beispielsweise mittels Laser oder Elektronenstrahl. Es handelt sich somit um eine werkzeuglose Produktion. Hieraus folgt, dass die Geometrie, beispielsweise eines mit Schneiden versehenen Kopfes eines Dentalfräsers, nicht durch die bei der Fertigung zu verwendenden Werkzeuge beschränkt ist. Vielmehr können Hohlräume, Hinterschnitte, Spülkanäle, Lüftungskanäle oder Ähnliches, in einem einzigen Arbeitsschritt mittels des additiven Verfahrens hergestellt werden. In the additive manufacturing process, which allow the production of medical instruments, such as steel, ceramic, hard metal, titanium or plastic, it is usually assumed that a powdery material. This is melted in layers, for example by means of laser or electron beam. It is therefore a tool-free production. It follows that the geometry, for example, a cutting head of a dental cutter, is not limited by the tools to be used in the production. Rather, cavities, undercuts, flushing channels, ventilation ducts or the like can be produced in a single step by means of the additive method.

Bei den zur Rede stehenden medizinischen Instrumenten handelt es sich im Wesentlichen um sehr kleine Bauteile (insbesondere Dentalbohrer oder Dentalfräser). Die Menge des additiv aufzutragenden Materials ist somit gering. Hierdurch ergibt sich die Möglichkeit, eine sehr schnelle und damit sehr kostengünstige Fertigung von hohen Stückzahlen zu ermöglichen. The medical instruments in question are essentially very small components (in particular dental drills or dental cutters). The amount of additive to be applied material is thus low. This results in the possibility to enable a very fast and therefore very cost-effective production of high volumes.

Das erfindungsgemäße Herstellungsverfahren eignet sich sowohl zur Einzelfertigung jeweils eines einzigen Instruments, als auch zur gleichzeitigen Fertigung einer Vielzahl von Instrumenten in einer gemeinsamen Vorrichtung zur additiven Fertigung. The manufacturing method according to the invention is suitable both for the individual production of a single instrument, as well as for the simultaneous production of a plurality of instruments in a common device for additive manufacturing.

Das erfindungsgemäß zu verwendende additive oder generative Herstellungsverfahren sieht somit vor, ein medizinisches Instrument schichtweise direkt strukturiert und schichtübergreifend herzustellen. Dabei ist es besonders günstig, wenn das Instrument in vertikaler Anordnung gefertigt wird. Hierdurch ist es insbesondere bei rotierenden Instrumenten möglich, diese rotationssymmetrisch zu einer Rotationsachse zu fertigen, so dass keine Nacharbeiten erforderlich sind. Weiterhin kann bei einer vertikalen Anordnung auf die Ausbildung von Stützbereichen, welche nachfolgend wieder entfernt werden müssten, ve reichtet we rd en^ The additive or generative production method to be used according to the invention thus provides for the direct structuring of a medical instrument in a layered manner and across layers. It is particularly advantageous if the instrument is manufactured in a vertical arrangement. This makes it possible in particular for rotating instruments to produce these rotationally symmetrical to a rotation axis, so that no reworking are required. Furthermore, the training of support regions which would have to be subsequently removed again in a vertical arrangement, ve reichtet we rd s ^

Die additive Fertigung erfolgt erfindungsgemäß bevorzugterweise unter Verwendung eines Pulvermaterials oder ähnlichem. Dabei wird das Instrument in einem mit dem Pulver gefüllten Behälter schichtweise aufgebaut. Die jeweilige obere Pulverschicht wird durch selektives Laserschmelzen, selektives Lasersintern, durch Elektronenstrahlauftragsschweißen oder ein DLD-Verfahren erzeugt. Nachfolgend wird die nächste Pulverschicht aufgebracht, wobei das Pulver formgenau zur Erzeugung des Instruments mittels des Lasers oder Elektronenstrahls oder in anderer Weise aufgeschmolzen und verfestigt wird. Übliche Schichtstärken liegen dabei zwischen 20 pm und 100 μηο. The additive production according to the invention is preferably carried out using a powder material or the like. The instrument is built up layer by layer in a container filled with the powder. The respective upper powder layer is produced by selective laser melting, selective laser sintering, electron beam deposition welding or a DLD process. Subsequently, the next powder layer is applied, wherein the powder is accurate to produce the instrument by means of the laser or electron beam or otherwise melted and solidified. Usual layer thicknesses are between 20 pm and 100 μηο.

Die additiven Herstellungsverfahren erlauben eine Herstellung von medizinischen Instrumenten, deren mechanische Eigenschaften weitgehend denen des verwendeten Grundwerkstoffs entsprechen. Es ergeben sich große Bauteildichten, welche fast 100% betragen können. Hieraus folgt, dass die erfindungsgemäß hergestellten Instrumente eine hohe Festigkeit aufweisen und somit sowohl eine lange Lebensdauer als auch eine gute Schneidleistung haben. The additive manufacturing processes allow the production of medical instruments whose mechanical properties largely correspond to those of the base material used. This results in large component densities, which can be almost 100%. It follows that the instruments according to the invention have a high strength and thus have both a long life and a good cutting performance.

In besonders günstiger Ausgestaltung der Erfindung ist vorgesehen, dass das medizinische Instrument in einer Mischbauweise oder Hybridbauweise erzeugt wird. Dabei ist es beispielsweise möglich, einen Schaft mit einem Einspannbereich spanend aus einem Halbzeug zu fertigen und nachfolgend beispielsweise den mit den Schneiden versehenen Kopf oder zumindest einen Teil des Kopfes mittels eines additiven Verfahrens zu fertigen. Diese Lösungsvariante kann sich dann als besonders vorteilhaft erweisen, wenn die spanende Fertigung eines Werkzeugs im Bereich seines Schaftes und seines Einspannbereiches automatisiert erfolgen kann und lediglich die Herstellung des Kopfes in einem einzigen additiven Herstellungsschritt vorgenommen werden kann. Es ist jedoch auch möglich, beispielsweise lediglich einen Kopf eines Instruments additiv zu fertigen und diesen dann auf andere Weise mit einem vorgefertigten Schaft zu fügen, beispielsweise durch Reibschweißen, Laserschweißen oder Ähnliches. In a particularly favorable embodiment of the invention, it is provided that the medical instrument is produced in a mixed construction or hybrid construction. In this case, it is possible, for example, to manufacture a shank having a chucking area from a semi-finished product and subsequently to produce, for example, the head provided with the cutting edges or at least a part of the head by means of an additive method. This solution variant can prove to be particularly advantageous when the machining of a tool in the region of its shaft and its clamping area can be automated and only the production of the head can be made in a single additive manufacturing step. However, it is also possible, for example, to additively manufacture only one head of an instrument and then to add it in another way with a prefabricated shaft, for example by friction welding, laser welding or the like.

Somit wurde erfindungsgemäß erstmals eine Möglichkeit geschaffen, eine industrielle Großserienfertigung medizinischer Instrumente mittels additiver Verfahren vorzunehmen. Die Verwendung derartiger Verfahren auf dem Medizinsektor wurde bisher nicht in Betracht gezogen, da additive Herstellungsverfahren meist nur für die Prototypenfertigung oder für die Einzelfertigung verwendet werden. Thus, according to the invention, a possibility was created for the first time to carry out industrial mass production of medical instruments by means of additive processes. The use of such methods in the medical sector has hitherto not been taken into consideration, since additive manufacturing methods are mostly used only for prototype production or for individual production.

Durch das erfindungsgemäß vorgesehen Verfahren ist es somit möglich, aus unterschiedlichsten Materialien (Titan oder Titanlegierungen, Keramik, Kunststoff, Stahl, Hartmetall oder Ähnlichem) beliebige Geometrien, insbesondere der Köpfe von medizinischen Instrumenten zu erzeugen, die ein hohes Maß an Festigkeit aufweisen und eine Gestaltung, unabhängig von den Beschränkungen durch Werkzeuge ermöglichen. By means of the method provided according to the invention, it is thus possible to produce from arbitrary materials (titanium or titanium alloys, ceramic, plastic, steel, hard metal or the like) any geometries, in particular the heads of medical instruments, which have a high degree of strength and a design , regardless of the limitations allowed by tools.

Das erfindungsgemäße Verfahren eignet sich auch dazu, additiv hergestellte Bereiche des medizinischen Instruments mittels eines abtragenden Verfahrens nachzubearbeiten. So ist es beispielsweise möglich, die Schneiden, beispielsweise eines Kopfes eines Fräsers, mittels eines abtragenden Laserverfahrens zu schärfen oder zu kalibrieren. Dies kann beispielsweise auch erfolgen, um den Rundlauf eines rotierenden medizinischen Instruments zu verbessern. Im Folgenden wird die Erfindung anhand eines Ausführungsbeispiels in Verbindung mit der Zeichnung beschrieben. Dabei zeigt: The method according to the invention is also suitable for reworking additively produced areas of the medical instrument by means of a removing method. For example, it is possible to sharpen or calibrate the cutting edges, for example a head of a milling cutter, by means of a laser ablation process. This can also be done, for example, to improve the concentricity of a rotating medical instrument. In the following the invention will be described by means of an embodiment in conjunction with the drawing. Showing:

Fig. 1 eine schematische Seitenansicht eines zu verwendenden Halbzeugs, Fig. 2 einen Fertigungsschritt mit der Herstellung eines Schaftes, 1 shows a schematic side view of a semi-finished product to be used, FIG. 2 shows a production step with the production of a shank,

Fig. 3 ein fertig aufgebautes additives medizinisches Instrument in Form eines Bohrers oder Fräsers, 3 shows a ready-made additive medical instrument in the form of a drill or milling cutter,

Fig. 4 ein Schliffbild des typischen Gefüges von gezogenem Stahl mit anschließender Wärmebehandlung, und Fig. 4 is a micrograph of the typical structure of drawn steel followed by heat treatment, and

Fig. 5 ein Schliffbild eines durch ein additives Laseraufschmelzverfahren erzeugten Werkstoffs. 5 is a micrograph of a material produced by an additive laser reflow process.

Die Fig. 1 zeigt als Ausgangsmaterial für ein kombiniertes Herstellungsverfahren ein Halbzeug 1 , welches in Form eines Zylinderstiftes oder Drahtes, ausgebildet ist. Fig. 1 shows as a starting material for a combined manufacturing process, a semi-finished product 1, which is in the form of a cylindrical pin or wire.

In einem nächsten Arbeitsschritt wird das Halbzeug spanend bearbeitet, um einen Schaft 2 mit einem Einspannbereich 3 und einem Hals 4 zu erzeugen. Dieses Zwischenprodukt wird anschließend mittels eines additiven Verfahrens fertiggestellt, indem schichtweise Material zur Erzeugung eines mit Schneiden versehenen Kopfes 5 aufgebracht wird. In a next step, the semifinished product is machined to produce a shaft 2 with a clamping area 3 and a neck 4. This intermediate product is then finished by means of an additive process by applying layered material to produce a trimmed head 5.

Falls erforderlich, kann eine Schärfung der Schneiden mittels eines abtragenden Verfahrens, beispielsweise eines Laserabtragverfahrens, erfolgen. If necessary, a sharpening of the cutting by means of a removing process, for example, a laser ablation process, take place.

Die Figuren 4 und 5 stellen Schliffbilder dar, aus denen sich ein Vergleich zwischen einem herkömmlich erzeugten Werkstoff und einem mittels eines additiven Verfahrens erzeugten Werkstoff ergibt. FIGS. 4 and 5 are micrographs showing a comparison between a conventionally produced material and a material produced by an additive method.

Bei dem in Figur 4 gezeigten Schliffbild handelt es sich um einen konventionell hergestellten Werkstoff, welcher das typische Gefüge eines gezogenen Stahls mit anschließender Wärmebehandlung aufweist. Dabei sind deutlich die längs angeordneten Karbide in der martensitischen Grundmasse zu erkennen. The grinding pattern shown in FIG. 4 is a conventionally produced material which has the typical structure of a drawn steel with subsequent heat treatment. The longitudinal carbides in the martensitic matrix are clearly visible.

Im Gegensatz hierzu zeigt die Figur 5 einen Schliff eines mittels eines additiven Laseraufschmelzverfahrens erzeugten Werkstoffs. Dabei ist in der Gefügeansicht deutlich ein grobes, martensitisches Gefüge mit feinen Karbidausscheidungen zu erkennen, welche keine besondere Anordnung aufweisen. Als vorteilhaft erweist es sich bei additiv hergestellten Werkstücken, dass diese keine Härterisse bilden, so wie dies bei konventionell erzeugten Werkstücken der Fall ist. In contrast, FIG. 5 shows a grinding of a material produced by means of an additive laser reflow process. In the microstructural view, a coarse, martensitic microstructure with fine carbide precipitations can be clearly seen, which have no special arrangement. It proves to be advantageous in additively produced workpieces that they do not form any hardening cracks, as is the case with conventionally produced workpieces.

Claims

Ansprüche claims 1 . Verfahren zur Herstellung eines medizinischen Instruments, dadurch gekennzeichnet, dass dieses zumindest zum Teil mittels eines additiven Herstellungsverfahrens hergestellt wird. 1 . Method for producing a medical instrument, characterized in that it is produced at least in part by means of an additive manufacturing method. 2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass ein Schaft (2) mit einem Einspannbereich (3) und/oder zumindest ein Teil eines mit Schneiden versehenen Kopfes (5) spanend aus einem Halbzeug gefertigt wird und dass nachfolgend zumindest ein Teil eines Kopfes des Instruments additiv erzeugt wird. 2. The method according to claim 1, characterized in that a shank (2) with a clamping area (3) and / or at least a part of a provided with cutting head (5) is made of a semi-finished metal and that subsequently at least a portion of a head of the instrument is generated additive. 3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das Instrument mit vertikaler Anordnung seiner Rotationsachse additiv gefertigt wird. 3. The method according to claim 1 or 2, characterized in that the instrument is manufactured additive with a vertical arrangement of its axis of rotation. 4. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass als additives Verfahren ein selektives Laser-Auftragsverfahren, ein selektives Laser- Sinterverfahren oder ein Elektronenstrahl-Auftragsschweißverfahren angewendet wird. 4. The method according to any one of claims 1 to 4, characterized in that is used as an additive method, a selective laser deposition method, a selective laser sintering method or an electron beam deposition welding method. 5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass zumindest der additiv gefertigte Teil des Instruments aus Stahl, Keramik, Hartmetall, Titan, Titan- Legierungen oder Kunststoff besteht. 5. The method according to any one of claims 1 to 4, characterized in that at least the additively manufactured part of the instrument made of steel, ceramic, hard metal, titanium, titanium alloys or plastic. 6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass zumindest ein Teil des Kopfes (5) mittels eines abtragenden Verfahrens nachbearbeitet wird. 6. The method according to any one of claims 1 to 5, characterized in that at least a part of the head (5) is reworked by means of a removing process. 7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass das abtragende Verfahren ein Laser- Abtragsverfahren und/oder ein spanendes Verfahren ist. 7. The method according to claim 6, characterized in that the erosive method is a laser ablation method and / or a machining method. 8. Verfahren nach einem der Ansprüche 6 oder 7, dadurch gekennzeichnet, dass das abtragende Verfahren zur Schärfung von Schneiden oder zur Verbesserung des Rundlaufs des Instruments verwendet wird. 8. The method according to any one of claims 6 or 7, characterized in that the erosive method is used to sharpen cutting or to improve the concentricity of the instrument. 9. Verfahren nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, dass das Instrument als Zahnbohrer, Fräser, Schleifinstrument, Schallspitze und/oder Sägeblatt ausgebildet ist. 9. The method according to any one of claims 1 to 8, characterized in that the instrument is designed as a dental drill, milling cutter, grinding instrument, sonic tip and / or saw blade.
EP15702693.1A 2014-02-26 2015-01-26 Method for producing a medical instrument by way of an additive method Withdrawn EP3110363A1 (en)

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