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Man Has 75% of Skull Replaced By 3D-Printed Materials

redletterdave writes "An un-named male patient in the U.S. has had 75 percent of his skull replaced with 3D printed materials. The undisclosed patient had his head imaged by a 3D scanner before South Windsor, Conn.-based Oxford Performance Materials (OPM) gained approval from US regulators to print the bone replacement. OPM's final skull replacement was built within two weeks, and inserted in the patient's skull in an operation performed earlier this week; this cutting-edge procedure was only just revealed on Friday. OPM's 3D-printed process was granted approval by the FDA back on Feb. 18, which means the company can now provide 3D printed replacements for bones damaged by trauma or even disease. The company says this technique could benefit more than 500 U.S. citizens each month, from injured factory or construction workers to wounded soldiers."

74 comments

  1. Dude by Anonymous Coward · · Score: 0

    This is so cool

    1. Re:Dude by JWSmythe · · Score: 3, Funny

      They forgot to mention that it was adamantite.

      --
      Serious? Seriousness is well above my pay grade.
    2. Re:Dude by craigminah · · Score: 3, Funny

      They also omitted that the procedure was done by Cyberdyne Systems.

  2. Backbone printing by M3.14 · · Score: 5, Funny

    Finally a solution for people without any backbone.

    1. Re:Backbone printing by Grayhand · · Score: 3, Funny

      Finally a solution for people without any backbone.

      Now if they can perfect brain transplants we can finally fix Congress.

    2. Re:Backbone printing by slick7 · · Score: 2

      Finally a solution for people without any backbone.

      Now if they can perfect brain transplants we can finally fix Congress.

      They did, just open a can of Spam. The hard part is giving them a soul that doesn't die on contact with such corruption.

      --
      The mind conceives, the body achieves, the spirit manifests.
    3. Re:Backbone printing by dreamchaser · · Score: 2

      Finally a solution for people without any backbone.

      Now if they can perfect brain transplants we can finally fix Congress.

      Not just Congress. There might even be hope for the majority of Redditors.

  3. Designer skulls by vanyel · · Score: 1

    ...taking body modification to a whole new level...

    1. Re:Designer skulls by K.+S.+Kyosuke · · Score: 3, Funny

      Can you spell "Minbari"? ;-)

      --
      Ezekiel 23:20
    2. Re:Designer skulls by slick7 · · Score: 0

      Can you spell "Minbari"? ;-)

      Can you spell, Sith?

      --
      The mind conceives, the body achieves, the spirit manifests.
    3. Re:Designer skulls by SteveFoerster · · Score: 1

      It'd be kind of ironic to be a bonehead when it isn't really bone....

      --
      Space game using normal deck of cards: http://BattleCards.org
    4. Re:Designer skulls by Skrapion · · Score: 1

      Au contraire! The replacement has small surface details etched into it to promote new bone growth.

      --
      The details are trivial and useless; The reasons, as always, purely human ones.
    5. Re:Designer skulls by SteveFoerster · · Score: 0

      Those devious Minbari have thought of everything....

      --
      Space game using normal deck of cards: http://BattleCards.org
    6. Re:Designer skulls by Anonymous Coward · · Score: 0

      Actually more like a Terminator, Wolverine or possibly Master Chief.

  4. This worries me by 93+Escort+Wagon · · Score: 2, Funny

    If printing skulls becomes common practice, it's going to make AdBlock a lot less effective. I really don't want to be seeing some banner ad just because I sat behind the wrong person on the bus.

    --
    #DeleteChrome
    1. Re:This worries me by Algae_94 · · Score: 3, Insightful

      Let's get this straight. You don't want to see any banner ads on a bus? When was the last time you saw a public bus?

    2. Re:This worries me by djbckr · · Score: 1

      Not sure whether to mark this "Funny" or "Insightful"... I guess I'll lose my mod points for this comment.

    3. Re:This worries me by Anonymous Coward · · Score: 0

      I've been blind since birth, you insensitive clod!

  5. Re:pics or it didnt happen by DFurno2003 · · Score: 0

    no balls

  6. Trauma by JamJam · · Score: 3, Interesting

    Trauma injury that caused 75% of the skull to be destroyed surely must have a huge impact on the brain. Hopefully the patient isn't in a vegetative state...

    1. Re:Trauma by Chris+Mattern · · Score: 2

      At the moment, we don't even know if it *was* trauma injury. I actually suspect it was not; disease that required replacement of the bone seems more likely, for exactly the reason you state. We don't know, because nobody seems to be reporting any details on the man's condition.

    2. Re:Trauma by jamesh · · Score: 1

      Trauma injury that caused 75% of the skull to be destroyed surely must have a huge impact on the brain. Hopefully the patient isn't in a vegetative state...

      I think there are other diseases that can cause bone loss, but google for "half a head" and you'll find some interesting pictures. Nowhere near 75% but still a significant amount of bone loss from trauma where the patient can still walk and talk.

    3. Re:Trauma by Anonymous Coward · · Score: 1

      The article mentioned Connecticut which isn't one of the vegetative states.

    4. Re:Trauma by crakbone · · Score: 2

      Think I met someone like that at the DMV.

    5. Re:Trauma by almechist · · Score: 1

      The article mentioned Connecticut which isn't one of the vegetative states.

      Clearly you don't live here.

    6. Re:Trauma by MozeeToby · · Score: 4, Insightful

      Article does mention that they scanned the patient's skull and made an as close to possible replica of it. I don't think that'd be an option if the guy got hit by a bus.

    7. Re:Trauma by Anonymous Coward · · Score: 0

      Cancer maybe? The article specifies just the possible application areas, not the actual condition of the patient. I was hoping they could insert some nifty carbon fiber composite to make the patient three meters tall and very difficult to kill.

    8. Re:Trauma by ByteSlicer · · Score: 1

      Looking at the picture of the implant, it was more like 75% op his skull cap. I don't think losing 75% of your skull would be survivable.

  7. The printers may be getting cheaper by Anonymous Coward · · Score: 0

    But what they fail to tell you is it takes hundreds of thousands of dollars to do anything with the output.

    I'll stick with the monochrome laser.

  8. Firearm? by stevegee58 · · Score: 1

    Yes, but will he be required to register it as a firearm?

    1. Re:Firearm? by K.+S.+Kyosuke · · Score: 1

      Only if he has a Picatinny rail on the crest.

      --
      Ezekiel 23:20
    2. Re:Firearm? by Anonymous Coward · · Score: 0

      Haven't seen a patent for a skul gun yet.

  9. This is nothing new. by sehlat · · Score: 1

    Politicians have had 100% skull replacement for centuries.

    1. Re:This is nothing new. by RoknrolZombie · · Score: 3, Insightful

      Hidden in the rectum != Replacement

  10. Actually 3D printed? by gatfirls · · Score: 2

    I'm curious if it is what we would consider 3d printed. Not that it isn't cool, I just know it's popular to latch onto a new buzztech word because of the press.

    1. Re:Actually 3D printed? by wonkey_monkey · · Score: 1
      You could always - yes, yes, I know, this is Slashdot - read the article. It's sparse on details, but it will at least tell you that

      Oxford Performance Materials adapted EOS P800 printing technology to use a special polyetherketoneketone (PEKK) material that has proved suitable for human implants.

      --
      systemd is Roko's Basilisk.
    2. Re:Actually 3D printed? by Dasuraga · · Score: 1

      You call it a buzzword, but being able to make things like this without requiring a mold is pretty different.

    3. Re:Actually 3D printed? by DerekLyons · · Score: 1

      Reading TFA and googling the machine mentioned, yes it's a 3D printer.

    4. Re:Actually 3D printed? by Celarent+Darii · · Score: 1

      An enormous difference, actually. I have a friend who works with prosthetics and the construction of the mold is often a large part of the cost in making things like joint replacements for hips. In some situations the mold is very costly, and it can only be done once - if it doesn't work they have to do the whole thing over. This is a huge leap forward.

    5. Re:Actually 3D printed? by Russ1642 · · Score: 1

      With a 3D printer you skip many steps in making something. In the past molds were made directly off of someone's limb. Now, they scan the limb into the computer and design the new part off of it. Computer design allows much more sophistication. Once the design is done you print directly from that and test the component on the individual getting treatment. If there's an issue you can make a minor fix to the design and print again. It's probably cheaper to take five stabs at printing something on a 3D printer than doing one version of the old process where you take a mold, do casts, modify them by hand, etc.

  11. Re:pics or it didnt happen by RoknrolZombie · · Score: 2

    Of course not, those require an advanced 3D printing technique that we won't see for at least a few more weeks.

  12. a vegetative state by DougOtto · · Score: 1

    Like Nebraska?

    --
    Solving Unix problems since 1989...
    1. Re:a vegetative state by Reverand+Dave · · Score: 4, Funny

      No, brain dead, more like Texas.

      --
      I got here through a series of tubes
  13. Wolverine! by Anonymous Coward · · Score: 0

    X-Men are here.

  14. Send us your bones by Mysteryprize · · Score: 1

    Sounds good, as long as they don't use squirrel bones as a raw material. http://www.youtube.com/watch?v=9exB1XR10ck

  15. boneless chickens by crakbone · · Score: 1

    Now if only they could use technology for the boneless chicken industry. Those poor chickens have been suffering for a long time.

  16. Futurama quote by jgunchy · · Score: 1

    "My only regret is that I have... Boneitis."

  17. no more helmets? by turkeydance · · Score: 1

    just imagine an integral shock absorbing modular skull. of course, a helmet protects more than the brain, but this is good news. i needed some.

    1. Re:no more helmets? by Anonymous Coward · · Score: 0

      We have one. It just has been outmoded by our predilection for high-kinetic-energy activities that frequently end abruptly at a tree or wall.

  18. All I want to know is... by multimediavt · · Score: 1

    ...can they print Roger Ebert a new jaw, because damn, that sucks!

  19. Not clear on the concept by Anonymous Coward · · Score: 0

    I don't get it, how does subjecting an injured and disfigured skull or other bone to 3D scanning help build a replacement? It seems to me the scanning has to occur before the injury or illness, otherwise you'll just be replacing a defective bone with an equally defective 3D printed replacement. So what, the guy in TFA just happened to have had his skull scanned right before the injury/illness occurred? Seems unlikely. Should we now all go and have all our bones scanned, just in case? Something doesn't add up here.

    1. Re:Not clear on the concept by the+biologist · · Score: 1

      The normal shape of a skull can be worked out easily from looking at lots of other people... the scanning of the patient allow the replacement piece to fit precisely with what remains of the original skull.

  20. Cousin Eddie? by jtownatpunk.net · · Score: 2

    Poor guy will never be able to ride a saucer sled down a hill again. "...if this gets dented then my hair just ain't gonna look right."

  21. seems like it might be a better alternative by HPHatecraft · · Score: 2

    to bamboo.

    Abstract

  22. Transparent Skull by Anonymous Coward · · Score: 2, Funny

    What? Tattoos? 1960s! Piercings? 1980s! These things where they burn you, or slice you? 2000s! No man, the next thing is to have your scalp removed and then you have a 3D-printed, transparent skull with LEDs mounted inside! Maybe even multi-color ones to indicate your mood!

  23. Re:pics or it didnt happen by godel_56 · · Score: 3, Interesting

    pics or it didnt happen

    You asked for it.

    http://www.technewsdaily.com/images/i/000/011/153/original/osteofab-cranial-device.jpg?1362591104

    TFA says they use some sort of plastic called polyetherketoneketone (PEKK) so I'm guessing structual strength won't be a major selling feature.

  24. Printing Private Parts for men and women :) by Anonymous Coward · · Score: 0

    It'll eventually happen sooner or later. :-p

  25. Re:pics or it didnt happen by the+biologist · · Score: 1

    That is the only picture which is getting passed around... but that replacement part is nowhere near 75% of the skull.

  26. How about a bullet-proof skull then? by heteromonomer · · Score: 1

    Can someone knowledgeable (i.e. not speculating) or working in the medical device industry explain why we can't use some really hard material like a titanium alloy or Kevlar to make the skull bullet-proof, especially for those in combat?

    1. Re:How about a bullet-proof skull then? by lister+king+of+smeg · · Score: 1

      Or while we are at it build in some tech, Hey they are replacing the skull after all why not put in a few things that may or may not come in handy later. For example cochlear implant with blue-tooth receiver when the person get older they will not need a operation to help their hearing and could make cell calls sans the annoying earbug in the meantime. they could also through in a few eeg sensors like the ones in the emotiv epoc headset only emebed in the new skull so you could mind control computers with the right software and training. they could also you could do all sorts of stuff with a manufactured head.

      --
      ---Saying gnome 3 is better than windows 8 not so much a compliment as it is damning with light praise.
    2. Re:How about a bullet-proof skull then? by Troll-in-Training · · Score: 3, Informative

      Can someone knowledgeable (i.e. not speculating) or working in the medical device industry explain why we can't use some really hard material like a titanium alloy or Kevlar to make the skull bullet-proof, especially for those in combat?

      Transfer of Kinetic Energy. If you just used a hard bullet proof material the kinetic energy would pass straight through and liquefy the brain.

      To make a bullet proof skull you would have to use a hard outer shell, a collapsable inner filler to absorb the kinetic energy and a hard inner shell to prevent spalling from shredding the brain. With current materials science it would be ridiculously thick and heavy and cause more problems than it would solve unless you could reinforce the spine and neck muscles, and it would have to be replaced/rebuilt after every impact.

      Take a look at the size and thickness of current combat helmets to see what I mean, and remember that current helmets will not stop a high caliber round or an armor piercing one in a direct impact. They only protect against shrapnel, glancing blows from assault rifle rounds and some light pistol rounds under the right conditions. They have to be discarded after one serious protective use as they are designed to stop the damage by sacrificing their structural integrity (they only stop one hit in the same spot).

    3. Re:How about a bullet-proof skull then? by Anonymous Coward · · Score: 0

      Because there aren't very many substances you can implant in a human body without having some kind of bad reaction to it - some kind of chemical reaction, or an allergic reaction, or bacteria building up on it or stuff like that. It's really hard to find any alloy that is tolerated inside the body and has reasonable strength characteristics. I'm surprised they could find something that could be 3d printed, and that would still be tolerated/not degrade inside a human.

    4. Re:How about a bullet-proof skull then? by Anonymous Coward · · Score: 0

      Considering soldiers don't even wear *helmets* that can stop rifle rounds, it is unklikely you could fit one in the space of the skull.

  27. Pre-deployment scan by ed314159 · · Score: 1

    Perhaps it should be standard practice for individuals in danger of serious trauma, such as members of the military, to undergo bone scans to provide templates for future replacements.

    1. Re:Pre-deployment scan by Celarent+Darii · · Score: 1

      Even better - how about for sports athletes and even every person of adult age goes to the doctor for a scan, and his skeleton is profiled and kept in a database for future use.

      Imagine what we could do if we could 3d print organs.

    2. Re:Pre-deployment scan by Anonymous Coward · · Score: 0

      Imagine what we could do if we could 3d print organs.

      We are getting there. http://www.youtube.com/watch?v=9RMx31GnNXY

  28. Re:pics or it didnt happen by knarf · · Score: 2

    TFA says they use some sort of plastic called polyetherketoneketone (PEKK) so I'm guessing structual strength won't be a major selling feature.

    The first hit on 'polyetherketoneketone' on a well-known search engine reads as follows:

    Advantages:
     
        High strength and toughness
        Chemical resistance
        Easy processing

    --
    --frank[at]unternet.org
  29. Brings new meaning to Print Head by Anonymous Coward · · Score: 0

    This brings new meaning to to the concept: Print Head

  30. They don't mention why he needed it by Anonymous Coward · · Score: 0

    So did he have his skull replaced just for giggles?

  31. Measure and model by andersh · · Score: 1

    I imagine it wouldn't take an insane amount of work to calculate the missing piece(s) of a scanned skull if they have other models to build on and software with math skills. There's a certain symmetry to all human skulls and only slight variations on the features' length and width etc. If you get hit by a bus, I imagine even a crushed skull or face would only require a lot of measurements of bone fragments and general size of the skull.

  32. What is good for humans is good for animals too by guinea+pig+C · · Score: 2

    In 2007, hunters shot an Alaskan bald eagle in the face and left her for dead, but she was then found by Jane Fink Cantwell, a bird conservationist. The bird’s entire upper beak had been shot off, the equivalent of losing a limb for birds that use their beaks for feeding and preening feathers, and clearly a death sentence for this majestic creature. Janie and her small volunteer staff at the Raptor Chapter kept the bird alive through liquid tube-feeding until mechanical engineer Nate Calvin was able create a prosthetic beak using a 3D printed nylon-based polymer. This magnificent bird of prey has since recovered to full health and has been named Beauty, and most deservedly so. http://birdsofpreynorthwest.org/beauty-and-the-beak-project/ This work was much more of an effort to increase the quality of the bird's captive life, rather than facilitate a release back into the wild with a new beak, but that should not restrict future projects. Contrary to initial thoughts, the beak actually needs to be ‘weaker’ not ‘stronger’ since the limitation is the connection points and the purchase available at those attachments. A new design is in the planning stages which will have ‘give points’ designed to allow the beak to flex before damage can be done at the connection points. http://i.ytimg.com/vi/y5BYcu1glK4/0.jpg The success of this project has led to the consideration of how 3D printing can be applied to the rehabilitation of other animals afflicted with similar damage. With the financial rise of the Chinese has also come a growth in the black market trafficking of endangered species body parts. These most famously include shark fins and tiger penis, sometimes for consumption, sometimes for pseudo-scientific medicine. One of the most horrific trends is the growth in illegal poaching of rhinos for their highly prized horns. A single specimen can now command up to $500,000 from Chinese buyers. In the most recent cases, well-funded poachers with high powered rifles and night vision goggles have been flying night raids into nature reserves by private helicopter. Upon immobilising these magnificent creatures, they proceed to hack off the horns, either with machetes or chainsaws. Unsurprisingly, few of the rhinos survive, situations quite similar to enormous sharks killed simply for a single fin. Printing a replacement horn for a rhino is obviously many magnitudes more difficult that printing a beak for an eagle, but this is a project that is being pursued. Designing a replacement is feasible from a mechanical standpoint, but has some incredible challenges from a practical viewpoint (controlling the animal during and after the procedure, limiting/assessing a ‘typical’ use/load scenario after attachment). Excerpted from "3D Printing - The Next Techologoy Goldrush"