Workaholics AnonymousKendal HanelBryant Pham

Konstantin IvanovHoang PhamRobert Scult

Anthony Tilley

Problem StatementDental implants are made

out of machined metalsTop component suffers

excessive wear

Material Selection CriteriaAvailable particle size and shape for micro-

feature PIMBiocompatibleWear ResistantLow oxygen and carbon content

Final Decision Post Implant – CP Ti Grade 1

Screw Hate – Al2O3

Powder SpecificationsAP&C Advanced

Ti Spherical Sieving Apparent Density

0-25um 32% 2.55 25-45um 65.5%+45um 2.5%

Inframat Advanced MaterialsAl2O3

Spherical Particle Size Apparent

Density3-4um Avg. 3.97 g/cm3

Manufacturing Process Mix powder Polypropylene, paraffin wax, and stearic acid binder at 65%

solids loading PIM using Archimedes screw heated barrel Immerse in heptane at 60°C Second stage Argon sweep gas for Titanium at 450°C max Vacuum sinter at 1250°C for 3 h for Titanium Finish Titanium with hot isostatic pressing Sinter at 1400°C for 2 h for Alumina

InspectionVisual and SEM (appearance)

Dye penetration (surface cracks)

Core X-ray (inner core defects)

Critical FunctionImproving wear resistance of the componentBiocompatibility of componentRemoving all machining stepsMaterial selection to improve propertiesHigh wear resistance from AluminaTitanium & Alumina fit biocompatibility

requirements

Market Shares Estimated $3.4 Billion in implant sales a year & growing at 10%/year“American Academy of Implant” estimated 3 million people with implants and 500k increase/year in US69% of adults (age. 35-44) have lost at least 1 permanent toothBy age 74, 26% of adults will have lost all of their permanent teeth.Europe ½ global market, while North America 2nd largest regionGrowth in the Asia/Pacific region being driven by China & is expected to increase the global size in coming years.15% Market Share @ 3 Implants/person

225,000 units/year

Failure CriteriaDoes not fit dimensional toleranceUnnecessary secondary finishing operationsHigh oxygen or carbon contentLow volume productionNo profitUnacceptable defects

Equipment CostWittmann Battenfeld Molding Machine + Robot

$130,000Scott Turbon Mixer Inc. Double Planetary Mixer Ipsen Vacuum Debind/Sinter Furnace

Production Cost$15,000 Mold made in ChinaHIP contracted to Pressure Tech Inc. @ $2000/cyclePart Volume

Post 0.173 Cap 0.128

0.73179 g/unit Ti @ $150/kg0.5052445 g/unit Alumina @ $26/kg$0.15/unit material$0.23/unit processing

$0.38/unit total

References http://www.wittmann-ct.com/lib/f_dbstream.php?tn=tab_file&fd=file&mt

=application/pdf&id=1079&hxfile&f=YearEnd2012.pdf

http://www.dental-tribune.com/articles/business/americas/11737_dental_implants_market_expected_to_double_by_2018.html

http://www.raymor.com/apc/products/titanium/#gr-1_0-45

American Association of Oral and Maxillofacial Surgeons

http://www.pressuretechnology.com/hot-isostatic-pressing.php

http://www.ncbi.nlm.nih.gov/pubmed/17257912

http://www.sciencedirect.com/science/article/pii/S0965997809001367

http://link.springer.com/article/10.1007%2Fs11837-011-0036-z