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High resolution electron beam melting

Objective

HiResEBM is a partnership between EU SMEs and RTD providers with the aim of developing an electron beam melting (EBM) additive manufacturing process to enable the fabrication of high resolution medical implants with optimised porous structures directly from metal powder. Currently the design of medical implants with porous structures is limited by production technologies not being able to implement complex 3D structures. These complex structures are used to improve the initial fixation strength and the long term osteointegration properties of implants which lead to better quality of life for the patients. However, many patients undergo revision surgery within five years of receiving the original implant. The objective of HiResEBM is to produce an efficient manufacturing process that will allow any designed porosity to be incorporated into any part of an implant – giving complete freedom to design the ‘optimum’ implant. The consortium is composed of several companies with resources and experiences in different fields relating to the technical barriers to be overcome during the project, such as:
- Expertise in electron beam gun design, to produce a new high precision EB system
- R&D experience in additive manufacturing with fine powders
- Coating processes used for the medical implant market
The advantage of the new EBM system are that any theoretically designed medical implant with complex 3D porous structures will be able to be cost effectively manufactured using the EBM system. Current systems are capable of producing ~3000 parts per year and are able to recycle unused powder for further processing. The ever increasing mean population age and the prevalence of degenerative bone diseases means that the demand for implants is going to increase significantly and place an even greater burden on our EU health care systems. By introducing new manufacturing technology and improving the revision rates saving of the order of €240M a year are possible.

Call for proposal

FP7-SME-2011
See other projects for this call

Funding Scheme

BSG-SME - Research for SMEs

Coordinator

ARCAM AB
Address
Krokslatts Fabriker 27A
431 37 Molndal
Sweden
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
EU contribution
€ 352 765,25
Administrative Contact
Ulric Ljungblad (Dr.)

Participants (5)

LINCOTEK TRENTO SPA
Italy
EU contribution
€ 224 686,25
Address
Via Al Dos De La Roda 60 Loc Cire
38057 Pergine Valsugana Tn
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Emanuele Magalini (Mr.)
SPARK POWER LTD
United Kingdom
EU contribution
€ 211 720,75
Address
East Beach Road 79
PO20 0ES Chichester
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Linda Partridge (Ms.)
LPW Technology Ltd
United Kingdom
EU contribution
€ 220 550,75
Address
Keckwick Lane Vanguard House Daresbury Science & Innovation Campus
WA4 4FS Daresbury
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Philip Carroll (Dr.)
TWI LIMITED
United Kingdom
EU contribution
€ 29 561
Address
Granta Park Great Abington
CB21 6AL Cambridge
Activity type
Research Organisations
Administrative Contact
Craig Coghill (Mr.)
ASOCIACION DE INVESTIGACION DE LAS INDUSTRIAS METALMECANICAS, AFINES Y CONEXAS
Spain
EU contribution
€ 11 616
Address
Parque Tecnologico Valencia - Avda. Leonardo Da Vinci 38
46980 Paterna
Activity type
Research Organisations
Administrative Contact
Manuel Sanchez (Mr.)