3D Printing: A Game-Changer for the Healthcare Industry

3D printing is playing an increasingly important role in the healthcare sector. Thanks to technologies such as FDM, FFF, and SLS, we can now design and rapidly produce custom medical devices that are more cost-effective, better performing, and tailored to patients' specific needs.

From custom orthotics to personalized clinical tools and specialized equipment, there are numerous applications.

Discover how industrial 3D printing is becoming a major asset for the medical field.

The Benefits of 3D Printing in Healthcare
Proven Technologies for Healthcare
Medical-Grade Materials
Applications of 3D Printing in Healthcare
3D Printing Use Cases in Healthcare
An Ideal Manufacturing Solution for the Medical Sector

The Benefits of 3D Printing in Healthcare

The technologies and materials used in medical 3D printing offer numerous advantages, including personalized care, reduced costs and faster production times.

Customized Products

In healthcare, customization is key, and 3D printing enables the production of parts adapted to specific needs. Each item can be tailored based on criteria such as shape, size, and texture.

• Custom orthotics tailored to the patient’s anatomy, enhancing comfort
• Custom medical devices that improve clinical practice
• The ability to produce parts with very complex geometries

Faster Production Times

3D printing allows for rapid manufacturing, drastically reducing development and production lead times, which means faster access to care.

Lower Production Costs

Unlike traditional methods, 3D printing doesn’t require expensive moulds or tooling. It’s ideal for producing small and medium quantities of specialized or custom medical equipment at low cost. Multiple different parts can even be printed in the same batch, which optimizes costs.

Lightweight and Durable

Thermoplastic materials are naturally low in density, making printed parts lighter while still offering strong mechanical properties. 3D printing techniques allow for fine-tuning of wall thickness, infill density, and layer structure to create parts that are both robust and lightweight, perfectly suited to medical requirements.

Proven Technologies for Healthcare

Various industrial 3D printing technologies can be adapted to the healthcare sector. FDM (Fused Deposition Modelling) and SLS (Selective Laser Sintering) offer reliable performance and use thermoplastic materials that meet the sector’s strict standards.

FDM/FFF 3D Printing

This technology is known for its speed and reliability. It supports short turnaround times and a wide range of materials, including biocompatible and sterilizable options, such as ULTEM 1010 and PC-ISO.

SLS 3D Printing

SLS does not require support structures, allowing for very complex geometries without design constraints. The resulting parts have excellent mechanical and isotropic properties, offering strength and durability.

Depending on the materials used and the level of requirements, the components can be biocompatible, which makes them well suited for medical applications. Post-processing options such as sealing can provide parts with a bacteria-resistant, smooth, washable, sterilizable, and visually appealing finish.

Additionally, SLS 3D printers can produce multiple parts with varied geometries in a single run, resulting in a significant productivity boost.

Medical-Grade Materials

Depending on the application, thermoplastic materials used in healthcare must meet strict requirements for biocompatibility, chemical resistance, durability, and sterilization. They must also be wear-resistant and easy to clean and disinfect. Some examples of materials used in the medical field include medical-grade PLA (polylactic acid), medical-grade PETG (polyethylene terephthalate glycol), medical ABS, certain TPUs (thermoplastic polyurethane), Nylon 11 and 12, PC and PC-ISO (polycarbonate), polypropylene, PPSU (polyphenylsulfone), and even PEIs (polyetherimide) such as Ultem, as well as PEKKs (poly-ether-ketone-ketone).

Some medical applications demand even more specific properties. That’s why Solaxis offers a portfolio of thermoplastics that meet multiple industry standards.

For example:

• For biocompatibility: Genotoxicity ISO 10993-3, Cytotoxicity ISO 10993-5, etc.
• For sterilization: EtO, hydrogen peroxide gas plasma, steam autoclave, and more
  
  

Applications of 3D Printing in Healthcare

Industrial 3D printing has numerous applications in the medical field—from orthotics to equipment and medical tools (brackets, clamps, housings).

Orthotics

There was a time when patients had to adapt to orthotics. Now, thanks to 3D printing with thermoplastic materials, orthotics can be adapted to every detail of the patient’s unique anatomy—affordably and quickly. The types of orthoses that use 3D printing include: hand orthoses, wrist orthoses, finger orthoses, ankle orthoses, knee orthoses, exoskeletons, and braces.

Because production is based on digital design files, every stage of design, modification, and prototyping can be carried out quickly and easily to deliver perfectly fitted devices in record time.

Faster production also means lower labour and manufacturing costs, and fewer follow-up appointments for adjustments. The result: improved comfort and optimized performance for the patient.

Surgical Tools and Guides

3D-printed surgical guides have greatly improved the precision of procedures and patient recovery times. Additive manufacturing allows for the creation of personalized tools to assist surgeons during operations.

Designed from medical imaging (CT scans or MRIs), these guides serve as precise models to direct surgical instruments. Their benefits are numerous: reduced damage to surrounding healthy tissue, shorter operating times, and improved postoperative outcomes.

Some examples of surgical guides and tooling produced by 3D printing:

• Cutting guides

• Positioning guides

• Jigs for assembling instruments

• Forceps, handles, instrument pushers

• Clip-holders, instrument supports

• Custom retractors

• Contact tips for surgical robots

New Medical Instruments

Thanks to 3D printing technologies and materials, parts can be produced from a CAD design in just a few hours—no moulds or assembly lines required. Just an idea.

Finished products can be tested within days, with quick and low-cost design iterations. This is why many medical device manufacturers have embraced 3D printing for the development and production of new instruments.

Some examples of medical instruments produced by 3D printing:

• Fittings and adapters for respirators

• Fluid connectors

• Masks, ergonomic cushions

• Protective casings for sensitive devices

3D Printing Use Cases in Healthcare

Decision-makers often rely on real-world examples to assess the feasibility and benefits of a solution. Here are two case studies involving the use of 3D printing for custom orthotics and medical equipment.

Custom Orthotics via 3D Printing

The challenge: to produce multiple batches of durable, made-to-measure orthotics quickly and repeatedly. The chosen solution: laser powder bed fusion (SLS) using Nylon PA 11.

READ THE CASE STUDY

Medical Equipment via 3D Printing

The challenge: to quickly manufacture a small batch of fan blades to cool the interior of medical housings. The parts needed to be smooth and medical-grade. The solution: FDM 3D printing with PC-ISO, a medical-compliant material.

READ THE CASE STUDY

An Ideal Manufacturing Solution for the Medical Sector

3D printing is truly a breakthrough for healthcare, offering innovative solutions that improve patient care while reducing both costs and lead times.

By eliminating the need for moulds, it significantly lowers costs, especially for small batches and one-off parts. Fast turnaround means quicker patient treatment. And the freedom to design complex, lightweight, and durable components makes it easy to meet healthcare’s specific demands.

3D printing is booming. It’s transforming how surgeons plan and perform procedures, enhancing patients’ quality of life, and advancing the practice of medicine. With ongoing developments in materials and processes, industrial 3D printing is poised to become essential in the future of healthcare.