Bosch Advanced Ceramics 3D prints 1,400 MedTech components in a single batch | VoxelMatters - The heart of additive manufacturing

Bosch Advanced Ceramics reported a significant achievement in the development of a ceramic insulating sleeve for laparoscopic tools used in minimally invasive surgeries, exemplifying both precision and scalability in MedTech manufacturing.​ After a successful sampling phase, Bosch Advanced Ceramics scaled up production, achieving 1,400 parts per batch on a single build plate. This capacity enabled the company to efficiently meet the annual demand of 20,000 units, using CeraFab 3D printers from Lithoz and the LithaLox 360 Alumina material.

The project commenced with the challenge of designing a component with an external diameter of 1.3 mm and a wall thickness of just 90 µm. Such dimensions were critical to ensure the part’s functionality as an electrical insulator within the confined spaces of a laparoscopic instrument.​

In laparoscopic procedures, maintaining electrical insulation between conductive components is vital to prevent unintended currents that could compromise patient safety. The ceramic sleeve serves this essential function, highlighting the importance of its precise design and material properties.​

To achieve the required intricacy, Bosch Advanced Ceramics employed Lithoz’s LCM technology. This method offers exceptional precision and design flexibility, enabling the production of complex geometries that traditional manufacturing methods cannot achieve. The LCM process involves layer-by-layer photopolymerization, allowing meticulous control over the component’s features.​

The LithaLox 360 alumina material proved ideal due to its excellent thermal resistance, chemical stability, and electrical insulation properties. These characteristics are essential for components subjected to the demanding surgical sterilization and use conditions.​

Another critical factor in scaling production was Bosch Advanced Ceramics’ proprietary cleaning process. This automated method gently and effectively handled the fragile green parts post-build, removing excess material without damaging the delicate structures, thus maintaining quality and consistency across batches.​

Conventional manufacturing techniques, such as micro Ceramic Injection Molding (µCIM), often necessitate expensive micro-molds and lack the flexibility for rapid design modifications. In contrast, LCM technology eliminates the need for such molds and facilitates swift adjustments, making it ideal for producing complex ceramic components.​

Developing the insulating sleeve required multiple design iterations to balance structural integrity with electrical insulation properties. The AM technology allowed Bosch Advanced Ceramics to rapidly adjust designs and process parameters, leading to four tested iterations that optimized wall thickness and external diameter.​

Each design iteration underwent rigorous testing to ensure the component met stringent medical standards. This iterative process was crucial in achieving the desired performance characteristics, demonstrating AM’s adaptability in refining complex components.​