• The initiative is part of the ATILA research project —funded by the Ministry of Science and Innovation, the European Union and the State Research Agency- which is already producing its first results in our country, Spain. 

• A multidisciplinary consortium is leading the project, coordinated by AIDIMME with the active participation of the Research Foundation of the Hospital General Universitario de Valencia FIHGUV, the research group of Laser Applications and Photonics of the University of Salamanca ALF USAL and the company Meltio.

• The innovative aspect of the project lies in the use of welding wire for the first time (a less polluting process that generates significantly less material waste) compared to other additive manufacturing technologies such as metal powder.

• The ATILA research project focuses on studying and developing a highly protective additive manufacturing process based on direct metal deposition using multi-laser wire technology to process highly reactive materials.

Valencia (Spain) January 15, 2025.- The ATILA research project has announced today another important technological breakthrough while reviewing the research progress made throughout 2024. The Valencian research center Aidimme has installed a 3D printing technology prototype to create for the first time in Spain biomedical implants made of titanium alloys with the groundbreaking metal 3D printing technology developed by the Spanish multinational Meltio based in Linares (Jaén).

Progress on the ATILA project

The ATILA research project —funded by the Ministry of Science and Innovation,  the European Union and the State Research Agency— aims to study and develop a high-protection additive manufacturing process based on the direct deposition of metal wire using multi-lasers for the processing of highly reactive materials. It is formed by a multidisciplinary consortium leading the project, coordinated by AIDIMME with the active participation of the Research Foundation of the General University Hospital of Valencia FIHGUV, the research group of Laser Applications and Photonics of the University of Salamanca ALF USAL and the wire-laser metal 3D printing solutions developed by Meltio. The Spanish company has different solutions for industries such as: the Meltio M600 metal 3D printer, the Meltio Engine Integration Kit for Vertical Machining Centers, the Meltio Engine Integration Kit for Industrial Robots and the Meltio Robot Cell.

“To conclude and after the progress of the ATILA project research in 2024, we can confidently state that, while metallic additive manufacturing technologies using  powder as raw material (such as PBF-LB/M and PBF-EB/M) already exist and enable the production of Titanium alloy implants with significant advantages —including their adaptability to individual patients and the creation of three-dimensional structures that promote bone growth— they are not without limitations.”

Thanks to the ATILA project, a new implant manufacturing technology is being developed, known as DED-LB/M, which uses titanium welding wire as its feedstock.This approach offers a significant competitive advantage by assuring the quality of the implants produced while also reducing material waste. The key focus of this technology is to create preforms that closely approximate the final product, minimizing waste compared to traditional machining methods that start with a solid block of material.  This underscores the importance of the ATILA project, explains the management of the ATILA Project consortium.

During the year 2024, significant advancements have been made in the research and development of  manufacturing biomedical implants that comply with regulatory standards:

– A study was conducted to determine the geometric limitations of the DED-LB/M process when manufacturing parts with varying complexities. This included different degrees of inclination or producing cylinders with small diameters up to 3 mm. The maximum inclination angle that could be achieved without sagging was identified, as well as the minimum diameter achievable using a 1 mm of Ti6Al4V wire.

Figure 1: Different parts were fabricated to define geometrical constraints in Ti6Al4V in DED-LB/M technology.

– Simultaneously, thermographic controls for each manufacturing process using a camera that monitors the temperature at a specific point of each deposited layer. This was done to ensure that the required microstructural and chemical composition characteristics were met.

– The analysis of all this acquired data will help address challenges associated with processing Titanium, particularly its high reactivity with oxygen, ensuring compliance with the stringent requirements of health sector regulations. 

– Feasibility study of biomedical implant prototypes: The feasibility of manufacturing of different biomedical implant prototypes have been studied, including a stemless cage for bone graft (for the shoulder), a distal radius plate (for the forearm), a cranial implant without screw system (for the skull) and acetabular implant (for the hip).

 The Fundación de Investigación del Hospital General Universitario FIHGUV has provided the necessary implant designs (plans and STL files) to AIDIMME. These designs have been modified geometrically to adapt them to the capabilities of DED-LB/M technology, including the necessary rounding adjustments. These images show the preforms of implants obtained. Due to the required precision, these preforms will need to be machined for their final use, where the necessary machining and finishing processes will be carried out.

– Study of mechanical and microstructural properties: Currently, Ti6Al4V blocks in grades 5 and 23 have been fabricated to create specimens for mechanical tests, microstructural characterization and required heat treatments. In the coming months, this characterization/verification will be completed and implants will be fabricated for the first in vivo and in vitro tests conducted by FIHGUV.

– As part of the ATILA Project Dissemination plan, the Spanish multinational Meltio, a leading manufacturer of metal 3D printing solutions for industry,  hosted a webinar, with an attendance of 82 professionals from the healthcare technology sector. The session was titled “Transforming Healthcare: First Biomedical Titanium 3D implants printed with Meltio’s technology confirmation”.

Figure 2: Thermographic camera placed on the ATILA prototype and thermal history of several deposited Ti6Al4V layers in DED-LB/M technology.

During the webinar,  the ATILA Prototype was presented, along with, the chemical, thermal and microstructural characterization conducted to date. The manufactured demonstrators were showcased,  and future challenges in the ATILA Project were discussed.

This research project, formed by a consortium of different entities, investigates the different uses and applications of biomedical implants made from titanium, specifically Ti64-ELI., The project leverages Meltio’s unique metal 3D printing technology, provided by the Spanish multinational company based in Linares, Meltio. The main novelty is that for the first time in Spain,  research is focused on the potential applications of 3D-printed titanium parts using welding wire technology. Unlike other technologies, such as metal powder-based methods, welding wire technology is more efficient, produces less pollution, and generates less material waste, which helps to reduce the carbon footprint of the manufacturing process. 

The direct metal laser deposition (DED-LB/M) additive manufacturing process can build parts by adding raw material in the form of powder or wire. DED-LB/M technology using wire offers several advantages including lower process contamination compared to powder-based methods, a good deposition rate, relatively low costs and high raw material utilization (close to 100%).

One critical consideration in this process is the interaction between the metal and oxygen, which can be a significant challenge when working with highly reactive materials like titanium. 

During an additive manufacturing process, there is a tendency for the metal to absorb oxygen due to the increased temperatures during melting and the subsequent deposition of successive layers The oxygen content must not exceed the maximum limits specified in the relevant standards for implants. According to the UNE-EN ISO 5832-3:2017 standard for surgical implants, which covers metallic materials, part 3, the maximum oxygen content allowed is 0.2% for Ti6Al4V grade 5 and 0.13% for Ti6Al4V ELI. The ASTM F136-21 standard, which applies to Ti6Al4V ELI, sets an even stricter oxygen limit.

Figure 4: Proforma distal radius plate and acetabular implant proforma.

The use of shielding gas coaxial to the melt is characteristic of DED technology —which creates the part by melting the solid metal material creating the part layer by layer with Meltio’s 3D printer— to ensure high material deposition efficiency and print quality.

About FIHGUV:

The Fundación de Investigación del Hospital General Universitario de Valencia (FIHGUV) is a non-profit organization that, since 1999, has been carrying out multidisciplinary biomedical and clinical research using cutting-edge technology and collaborating with different agents of the innovation system with regional, national and international prestige (https://fihguv.es/). The Foundation manages the research of the Consorcio Hospital General Universitario de Valencia and its health department, always oriented towards the achievement of its objectives of promotion, impulse and development of scientific, health and biomedical research. 

Its facilities have several laboratories equipped with the necessary technology to support research projects of maximum relevance and to promote new formulas to improve medical and surgical processes. It also has a Clinical Research Unit, a Scientific Unit of Business Innovation funded by the AVI and a Simulation Center for the training of professionals, as well as a television set to improve the dissemination of science and innovation carried out by researchers and medical professionals. 

With 35 research groups, it has published more than 1500 articles, 50 book chapters and 13 books, registering 18 patents and receiving 22 awards. In 2022, it achieved funding for 54 competitive projects, an increase of 12.5% over 2021. In innovation, the FIHGUV has led innovative projects, such as the first Chair of Robotic Surgery in Spain and collaborations with ITT and universities. The Foundation also hosts various structures of excellence such as research groups belonging to the CIBER (CIBER-ONC and CIBER OBN) and the new Biomodels and Biobanks Platform (SAIBSAL) of the Spanish Carlos III Health Institute.

About USAL: 

At the University of Salamanca (USAL), a digital twin of the new titanium 3D printing prototype is being developed together with AIDIMME and MELTIO using laser welding wire technology and studying nanostructuring using ultrashort pulse lasers for the improvement of biomedical implants.