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Individual Patient Solutions - IPS Implants

Individual Patient Solutions

IPS Implants®

The right "customized" choice for every patient

Patient-specific implants, planning aids, and anatomical models are made from various materials using state-of-the-art fabrication technologies. Thanks to computer-based planning and functionalized patient-specific implants, preoperative planning can be implemented in surgery with unprecedented precision.
Based on the potential planning in our IPS CaseDesigner® software and subsequent case treatment and communication in the IPS Gate®, you will then receive an IPS® implant fabricated to your wishes. As a result, the IPS® product range offers a versatile service in terms of patient-specific implants.
 

Advantages of our patient-specific solutions

Planning process

Planning process

  • Maximum mobility, flexibility and functionality through simple and efficient interaction with the user via the IPS Gate®. 
  • Holistic service with planning, production and shipping from a single source, eliminating the need to coordinate several service providers.
  • Provision of three-dimensional planning data and various planning options provide a high degree of planning reliability.
  • Efficient, time-saving case processing results in planning times of between only 5 and 20 working days, depending on the respective indication.
Drill and marking guides

Drill and marking guides

  • High planning and implementation reliability thanks to exact determination of the plate position and screw holes.
IPS® Implant

Implant

  • Broad selection of materials leads to a wide range of choices for the best possible patient care. 
  • Additive manufacturing technology provides complete freedom of design for implants as well as maximum flexibility and stability.
  • Rounded atraumatic edges for patients as trimming or bending are not required. 
  • Implant based on the individual CT scan of the patient is already checked for a perfect fit before it is shipped

IPS Implants®

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Individual Patient Solutions - IPS
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IPS Implants® Preprosthetic

IPS Implants® Preprosthetic

  • Functionally stable, immediate dental rehabilitation
  • No bone augmentation necessary
  • Remote fixation from the soft tissue penetration point of the abutment
  • Significant reduction in the treatment duration
  • Immediate postoperative loading possible
IPS Implants® Orthognathics

IPS Implants® Orthognathics

  • Additively manufactured implants, drill and marking guides or splints based on individual patient data
  • Orthognathic case planning using IPS CaseDesigner® planning software
  • Targeted predetermination of the fixations in an anatomically reliable environment and of the osteosynthesis screws to be used
IPS Implants® MI Orthognathics

IPS Implants® MI Orthognathics

  • Orthognathic case planning using virtual planning software IPS CaseDesigner®

  • Minimally invasive transfer of virtual planning to the OR with L1® MI Orthognathics instruments

  • Additively manufactured drill and marking guides, splints and implants, based on individual patient data

  • Integrated individual correction of the spina nasalis anterior (nasal spinous process)

  • Suture holes for fixation of the nasal septum

IPS Implants® Cranium

IPS Implants® Cranium

  • Versatile choice of materials: Polyetheretherketone (PEEK), ultra-high molecular polythylene (marPOR®), Addative Manufacturing Titanium (AMTi), titanium mesh or solid titanium
  • Complete design freedom of the implants through additive manufacturing technology, osteoconductive designs possible
  • Optional marking guides are available for an exact fit of the implant on the defect area
IPS Implants® Midface Orbita

IPS Implants® Midface Orbita

  • Additively manufactured implants in different design options based on the patient's individual CT data
  • Mirroring of the intact bones and adaptation to the predominant anatomical environment
  • Attachment of insertion vectors, navigation markers and depth gauges
  • Drainage functions for unhindered outflow of haematomas
  • Atraumatic implant margin allows soft-tissue-friendly insertion
IPS Implants® Mandible Reconstruction

IPS Implants® Mandible Reconstruction

  • Additively manufactured implants based on the patient's individual CT data
  • Optimisation of graft lifting from the fibula, scapula or Iliac Crest with the aid of accurately fitting drill and marking guides
  • Mirroring of the intact bones and adaptation to the predominant anatomical environment
  • Best possible three-dimensional fitting accuracy
IPS Implants® Distraction

IPS Implants® Distraction
 

  • Fixation plates based on the patient's individual CT data, already checked for optimal fit at the factory
  • Available as IPS® distractors with modified standard or special components
  • The standard distractors from the KLS Martin range serve as a basis
  • Heatmap of the bone thickness in the area of the attached distractors
  • Planning and securing the distraction vectors
IPS Implants® Transformation

IPS Implants® Transformation

  • Using custom-made guides and implants for frontal sinus setback and orbital rim contouring, mandible angle reduction and chin reduction with a broad choice of materials

  • Polyamide or titanium guides offering variability in design, such as bone-based or occlusal-based mandible angle guides

  • Onlays in different materials for maxillary and mandibular augmentation: marPOR®, PEEK and Additive Manufacturing Titanium 

  • Ideal complement: resorbable implants from our SonicWeld Rx® system for frontal sinus setback fixation 

IPS Implants® TMJ Prosthesis

IPS Implants® TMJ Prosthesis

Innovative Solutions x Established Workflow

  • Postoperative reconstruction of movement through anatomically oriented fossa and condyle design
  • Flexible design for individual needs
  • Mechanical safety with IPS inSilico® x VIT

The easy way to IPS Implants®

We offer a holistic service from case preparation to shipment of the individually manufactured implant. Thus, there is always only one contact person for you. Find out here how the process is put together.

1. Case creation in the IPS Gate®

1. Case creation in the IPS Gate®

To create a case, patient data and patient scans are uploaded to the IPS Gate®.

2. Planning phase

2. Planning phase

During the planning phase, planning meetings are arranged with you and our IPS® Designer. All important data concerning the case are summarized in a case-specific documentation.

3. Release

3. Release

If the design meets your requirements, you can release the design digitally for production directly via the IPS Gate®. Simultaneously, you will receive the commercial offer and confirm it by sending the order.

4. Production

4. Production

As soon as the approval has been obtained, production of the IPS Implants® starts using the latest manufacturing technologies.

5. Shipment

5. Shipment

The IPS® products are sent to you. The total processing times vary depending on the indication. You can find more detailed information on the processing times here.

Materials of the IPS Implants®

We offer a wide range of materials that can be used for different indications. 

The implants shown are typical case examples. Individualized treatment concepts are possible. Please ask us about this at your planning meeting. Further details on the different materials can be found in the respective drop-down menu.

AM-titanium

Additive manufacturing: Completely free surfaces can be generated without tools and devices. This allows for hitherto unprecedented options in surface design. Correction processes are no longer required.

Material: Ti-alloy Ti6Al4V

Benefits:

  • Complete freedom of design of the material and its surface
  • High stability
  • Open structures are possible

Electrochemical surface finishing

Finishing of the surface of additively-manufactured titanium implants with IPS® by uniform polishing

Function: 

  • Electrochemical machining of the surface of metallic components by diving in material-specific electrolyte 
  • Component = anode, electrolyte container = cathode 
  • Connecting a power source creates a closed circuit

Advantages: 

  • Optimization of surface structure: High gloss due to metallically pure surface and improved roughness values
  • Complex implant geometries possible 
  • Less and more uniform material removal compared to manual polishing

 

Titanium mesh

Compared with conventional osteosynthesis materials, titanium mesh is deep-drawn three-dimensionally. A special thermal process provides a closed material structure and best mechanical strength. The mesh is form-stable and not pre-damaged. Titanium mesh has excellent biocompatibility and offers accumulation potential for bone cells.

Material: pure titanium

Benefits:

  • Beneficial mechanical properties
  • Accumulation potential for bone cells
  • Optimal material for involved nasal sinuses
  • No osteosynthesis plates required for fixation

Solid titanium

Solid titanium is a high-strength reconstruction alternative to titanium mesh. Although it has been largely replaced by titanium mesh over the past few years, it still offers some advantages in certain applications - e.g. in terms of mechanical protection.

Material: pure titanium

Benefits:

  • High-strength reconstruction alternative
  • Complete three-dimensional replica of the defect under consideration of bone thickness
  • No osteosynthesis plates required for fixation

PEEK

PEEK is a high-strength, temperature-stable high performance polymer. Due to its physical properties, which closely resemble those of human cortical bone, it is the most commonly used plastic in orthopedics. Available in closed or pre-drilled designs.

Material: poly ether ether ketone

Benefits:

  • Very elastic, yet very hard and resistant at the same time
  • Optimal protective function for the patient
  • No increased thermal sensitivity
  • Low weight
  • Resistant to gamma irradiation and MRT imaging
  • Low formation of artefacts on X-ray images
  • Three-dimensional bone replacement

marPOR®

UHMWPE is a high molecular weight polyethylene that has been used in the medical field for surgical implants since many years. Specifically, it is an inert, non-absorbable polymer consisting of open and interconnecting pores. Thanks to its three-dimensionally interconnected and highly porous structure, marPOR® implants made of UHMWPE offer optimal conditions for potential vascularization and osseointegration.

Material: ultra high molecular polyethylene weight

marPOR®

Key Facts

  • Made of medical grade polyethylene (UHWMPE) 
  • Low weight
  • No increased thermal sensitivity
  • marPOR® implants promotes bone ingrowth and vascularization 
  • Allows for fluid transfer 
  • Flexible and porous while maintaining high strength 
  • Indicated for non-load bearing defects 
  • Sterile delivery of the marPOR® implants after validated Ethylene Oxide (ETO) sterilization 
  • 3-dimensional interconnecting pore structure with different pore sizes 
Handling and Fixation

Handling and Fixation

  • Sheets can be easily modified with a scalpel, scissors or drill 
  • Multiple easy fixation methods: 
    • Drill free screws 
    • Conventional miniplates and screws 
    • Medical sutures 

Generative manufacturing process,
additive manufacturing

Selective Lasermelting By loading the video, you accept YouTube's privacy policy. To play, accept YouTube cookies.

Selective Lasermelting

Selective laser melting (SLM) is a 3D printing process in the context of a generative manufacturing process.
Titanium powder is fed from a high pressure chamber into a working chamber via a scraper or roller. A laser beam is reflected into the working chamber with a mirror where it falls on the titanium powder. The impact of the laser beam melts the powder (hence the term laser melting) and compresses it. Once the laser has processed one working plane, the working platform (table) is lowered and a new layer of titanium powder is applied. Thus the workpiece is manufactured layer after layer. As the performance density of the laser is extremely high, this leads to highly compressed three-dimensional workpieces.
This manufacturing process allows the fabrication of patient-specific implants from additive manufactured titanium.
 

Selective Lasersintering By loading the video, you accept YouTube's privacy policy. To play, accept YouTube cookies.

Selective laser sintering and stereolithography

Selective laser sintering and stereolithography also count as generative manufacturing processes. Selective laser sintering (SLS) follows the same functional principle as selective laser melting, the difference being that the starting materials used are all materials with thermoplastic properties. Resin powder (e.g. polyamide (PA)) is a frequently used material. Drill and marking guides or anatomical models are manufactured using this method.

In stereolithography (SLA), the workpiece is positioned in a photopolymer liquid bath (e.g. epoxy resin) in which it is slowly immersed deeper and deeper. During each step a laser passes over the starting material to harden it in thin layers in order to create the desired shape.

The stereolithography process is the 3D printing process which has so far been in use the longest, so that a considerable amount of experience has been gained. In general this method is used for fabricating anatomical models.

Individual Patient Solutions - IPS conventional manufacturing

Conventional manufacturing technologies

PEEK, titanium mesh and solid titanium implants are fabricated with proven conventional manufacturing processes. This includes deep-drawing, milling, turning, or machining.

Legal basis for IPS Implants®

According to the regulation (EU) 2017/745, a custom-made product is a device specifically made in accordance with a written prescription of any person authorized by national law by virtue of that person's professional qualifications which gives, under that person's responsibility, specific design characteristics, and is intended for the sole use of a particular patient exclusively to meet their individual conditions and needs.

For this reason a separate inquiry is necessary in every IPS® case.

The written prescription is a release for the technical offer (design of the products). This is to be submitted in writing by the user at the same time as the required order for the economic offer if he/she agrees with the desired case planning.

Shipment is not permissible as a matter of principle without this mandatory regulatory document.

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