by Melissa Donovan
Medical manufacturing encompasses a host of objects from scopes used for surgical tools to pins and needles for a prosthetic knee. Today, anything can be manufactured with the help of three-dimensional (3D) printing.
Depending on the end use, many materials are available. These of course must adhere to medical and safety requirements.
Above: Formlabs’ BioMed Durable offers impact resistance as well as biocompatibility. 2. Surgical implants use silicon nitride; shown here is an implant made with a Lithoz printer.
According to John Anderson, medical marketing manager, Formlabs, “medical 3D printing materials must strike a complex balance, requiring material performance—such as strength or ductility—as well as biocompatibility for the application, such as long-term skin or mucosal membrane contact.”
“When it comes to manufacturing medical products, choosing the right material is critically important. In many cases, materials need to be biocompatible, autoclave sterilizable, and offer higher flexibility than comparable materials,” shares John Kawola, CEO, Boston Micro Fabrication (BMF).
Printer Specific
So what are some of those materials? Depending on the manufacturer, they might only be compatible with a specific printer.
BMF offers several materials for its microArch series of 3D printers that are designed for medical devices and life sciences. Its HTF is a high-temperature resistant, tough, and biocompatible resin. It is autoclave-sterilizable and ideal for applications where biocompatibility and flexibility are key. With an HDT of 152 degrees Celsius and biotech application compatibility, HTF offers versatility across demanding environments.
“I expect to see the need for flexible materials with features like biocompatibility or sterilizable only increase, as teams continue to turn to 3D printing for their research and production needs,” states Kawola.
Formlabs Nylon 11 Powder for selective laser sintering (SLS) is a biocompatible material frequently used for the production of custom orthotic insoles. Parts printed with it have demonstrated outstanding durability and resistance to heavy use. For stereolithography (SLA), Formlabs BioMed Durable offers impact resistance as well as biocompatibility.
With Lithoz’s ceramic 3D printers, resins or “slurries” are the main components. “For surgical implants, we might use bioresorbable tricalciumphosphate and hydroxyapatite. There are also implants from silicon nitride. Surgical tools are usually made from alumina, zirconia, or alumina-toughened zirconia. Orthodontic brackets are made of alumina, that can also be translucent. And in the dental field, a new development is dental restorations made from lithiumdisilicate,” shares Norbert Gall, head of marketing, Lithoz.
All Encompassing
Adversely, we can speak about materials in more abstract terms, meaning they aren’t designed for one specific brand of printer or type of technology.
Jeff Enslow, head of marketing, Impossible Objects, lists commonly used materials as titanium, cobalt chromium, and stainless steel powders for implants; biocompatible resins for dental and surgical applications; and polymers like PEEK for lightweight, durable components.
“Titanium is widely used for implants like cranial plates and hip replacements due to its strength, lightweight nature, and biocompatibility. Its resistance to corrosion ensures long-term durability in the body,” shares Rajeev Kulkarni, chief strategy and marketing officer, Axtra3D.
“As material science progresses, I anticipate a rise in high-performance composites, such as our carbon fiber material reinforced with polymers such as PEEK, which offer exceptional strength-to-weight ratios similar to aluminum, and superior thermal and chemical resistance,” foresees Enslow.
Kulkarni says PEEK is favored for a number of reasons, but used a lot in spinal implants and orthopedic devices, “offering biocompatibility, lightweight properties, and the ability to mimic bone-like stiffness. Ceramic-filled polymers are ideal for dental and orthopedic applications, combining strength and precision for crowns, bridges, and mold inserts.”
While there are a variety of materials used, Simon Leitl, director development, freeformer, ARBURGadditive says “the decisive factor here is the corresponding requirements for the respective product. A resorbable implant is usually manufactured using an extrusion-based process, as the appropriate materials are available and may already be known from conventional processes such as injection moulding. In the Arburg Plastic Freeforming process, for example, plastic granulates certified for medical use can be used. The polyjet process is particularly suitable for anatomical models, as the surfaces and coloring are very good here.”
Another example, “biocompatible resins are commonly used in SLA, hybrid photosynthesis, digital light processing printing for dental aligners, surgical guides, and hearing aids. These resins meet strict standards and provide high precision,” says Kulkarni.
While all of these materials are used, Kulkarni sees in the future “growth in bioresorbable materials for implants, which could naturally absorb into the body over time. Additionally, the rise of bioprinting materials, such as hydrogels and bio inks, could open possibilities for tissue engineering and organ printing, shifting the focus to regenerative solutions. While current materials remain key drivers, advanced polymers and biocompatible composites will further expand capabilities in medical manufacturing.”
“Both SLA and SLS 3D printing are used in the medical field. However, SLA materials will likely remain the most popular method for medical additive manufacturing (AM) due to their versatility. Over the next few years, it’s likely that new biocompatible materials will expand 3D printing applications to cellular, tissue, and organ creation,” adds Anderson.
Future At Work
The materials used to manufacture medical parts range from titanium to PEEK. Technological advancements mean the future is real in terms of biocompatible materials, as this will only further increase AM’s use in this field, allowing for the creation of organs and tissue.
Apr2025, Industrial Print Magazine
