CUSTOM-MADE MEDICAL IMPLANTS MANUFACTURED WITH DED-WL METAL 3D PRINTING TECHNOLOGY – A RESPONSE TO ON-SITE MEDICAL CHALLENGES - “I.M.P.R.I.N.T

Project I.M.P.R.I.N.T. – Custom-Made Implants Using DED-WL Metal 3D Printing

I.M.P.R.I.N.T. is a pioneering initiative addressing the critical demand for personalized, on-site medical solutions in military and space operations. The project leverages Directed Energy Deposition – Wire-Laser (DED-WL) 3D printing technology to develop a deployable system for the fabrication of patient-specific implants such as cranial plates and hip prostheses—directly in the field, under extreme conditions.

Conventional powder-based metal 3D printing technologies are limited by their infrastructure needs, power consumption, and high operating costs, making them unsuitable for remote or mobile applications. In contrast, DED-WL systems like the Meltio™ 450 offer a compact, low-energy, and logistics-friendly solution that can be operated with standard power supplies and minimal setup. Utilizing medical-grade titanium and stainless steel, this method enables the production of implants with excellent mechanical properties, comparable to or exceeding those made via traditional methods.

Preliminary testing has validated the structural integrity and performance of DED-WL components, confirming their suitability for clinical use. The project will culminate in the development of Technology Readiness Level (TRL) 6 prototypes and a comprehensive Standard Operating Procedure (SOP) that outlines the full development pipeline—from diagnostic imaging and CAD modeling to final post-processing.

The global orthopedic implant market exceeds $25 billion and is expected to grow at a CAGR of 6.1% through 2030, driven by rising demand for personalized care, aging populations, and advancements in medical technology. Despite this growth, the market still lacks efficient, field-deployable solutions for custom implants in high-risk environments.

I.M.P.R.I.N.T. presents a transformative dual-use opportunity, with potential applications in defense, aerospace, civilian healthcare, and veterinary medicine. The project is now seeking strategic partners and funding to transition toward clinical validation, regulatory approval, and market deployment. With its focus on mobility, cost-efficiency, and adaptability, I.M.P.R.I.N.T. is poised to redefine personalized medical care in the most challenging environments.