Additive medical manufacturing of orthopedic implants, instruments, and components

Additive Manufacturing

Additive 3D-printing of orthopedic devices

ARCH is uniquely positioned to provide additive medical manufacturing in both of today's leading powder-bed fusion technologies—EBM (Electron Beam Melting) and DMLS (Direct Metal Laser Sintering)—on the industry's top-rated machines. Our expertise elevates the production and performance of implants, instruments, and components for orthopedic, spine, dental, surgical robotics, and life sciences applications.

 
Additive spinal implant
ARCH Additive, the orthopedic center of excellence

Leverage our expertise to produce the highest quality products and achieve the best clinical outcomes while reducing time to market. With multiple FDA-registered facilities we offer an expansive contract manufacturing supply chain that is diverse, scalable, and reliable.

Today's leading powder-bed fusion technologies

Backed by over a decade of experience in medical additive manufacturing, our team will determine the right solution for the development of your orthopedic implants and then guide you from sketch through FDA 510(k) submissions into production.

Electron Beam Melting (EBM)
Electron Beam Melting
 

The GE Arcam EBM Q10plus is optimized for orthopedic implants. It is particularly ideal for the production of high-volume, press-fit implants with advanced trabecular structures as derived from CT scans of individual patients. EBM has the ability to stack multiple layers of parts for maximum build capacity within the build space (200 x 200 x 180mm). The EBM process maintains an elevated surface temperature allowing for parts to be stress-relieved directly after melting. This results in low residual stresses final components. EBM technology allows for easily removed support structures that do not require wire EDM or secondary removal techniques, increasing productivity in post-processing.

Direct Metal Laser Sintering (DMLS)
Direct metal laser sintering
 

The high-fidelity resolution of the DMLS process enables fine part details and tight tolerances, achieved through the combination of atomized powder particles and a precise laser. When it comes to DMLS technology for additive manufacturing, the EOS M290 is the industry standard. Its 400-watt yb-fiber laser has precision optics for high-speed scanning up to 7.0 m/s and a focus diameter of 100μm. Argon gas is blown across the platform to ensure the quality of the laser beam and the stability of the melting process. The EOS platform uses a build plate made of the same material that is being printed. Parts are attached directly to the 250 x 250 x 325 mm build plate.

Lattice structures for enhanced osseointegration
Lattice structure osseointegration examples
 

Providing a distinct clinical advantage, lattice structures are replacing secondary coatings within the world of orthopedics. These optimized structures are excellent solutions for bone ingrowth and osseointegration. We develop optimal structures for initial fixation and bone ingrowth through the marriage of additive technology and software. With capabilities to generate a wide variety of lattice structures, we can create unique designs for your implant needs.

Additive and subtractive manufacturing expertise
Femoral implant additive manufacturing
 

The strategic combination of additive and subtractive manufacturing processes plus related finishing services multiplies our value to you. With expertise in the full range of services, ARCH Medical Solutions is your formula for success. We provide end-to-end support, from additive manufacturing, complex machining, and finishing, to validated processes and assembly.

Ball joint additive manufacturing
Spinal implants additive manufacturing
Humerus implant additive manufacturing
Learn how we can support your precision medical manufacturing needs.
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