Understanding the Cost Drivers of Metal Powders: The true costs associated with additive manufacturing processes are often not well understood. To fully grasp the actual manufacturing costs, and therefore the economic viability of AM, each aspect of the entire chain needs to be well understood and controlled. This presentation uncovers the costs and main cost controls surrounding the metal powders used in AM. Practical Implementation of PEKK Additively Manufactured Orthopaedic Devices: learn how much of the discussion surrounding implementation of additive manufacturing has been focused more on the machine and less on the material and process system, resulting in new structures that then needed to be considered for applications and validated for incorporation into new products.

2. CONTROLLING (POWDER) COSTS
IN ADDITIVE MANUFACTURING
Eric Bono, Carpenter Technology Corp.

3. World’s largest supplier of gas atomized powders
2
CENTRAL
& SOUTH
AMERICA
EUROPE
NORTH
AMERICA
Manufacturing
Specialty stainless
& tool steel powder
Nickel, cobalt,
steel alloys
powder
Ultrafine
powder
Reading, PA
Powder-to-part AM
Technology Center
Superalloy
powder
ASIA / APAC
Titanium
powder
AM wire
products (Ti, Ni,
Fe alloys)
Sales office

4. AM Cost Structure
3
We ALL need to better understand the true underlying costs associated with the
entire AM supply chain:
• Machine purchase price (and depreciation)
• Powder costs
• Energy
• Training
• Post processing
• Quality
• On and on…

5. AM Cost Structure
4
We ALL need to better understand the true underlying costs associated with the
entire AM supply chain:
• Machine purchase price (and depreciation)
• Powder costs
• Energy
• Training
• Post processing
• Quality
• On and on…

6. Labor
EquipmentMaterial
Major AM Cost Drivers
5

7. Labor
20%
Equipment
60%
Material
20%
Major AM Cost Drivers
6

8. Labor
20%
Equipment
60%
Material
20%
Major AM Cost Drivers
7
Why so much focus here???

9. Why the focus on powder costs?
8
• Easy to measure line item
• Easy to put pressure on suppliers
• Most visible system component
• (Inaccurately) seen as a high-margin item

10. Metal Powder Cost Drivers
9
• Powder chemistry requirements
• Particle Size Distribution (PSD)

11. Metal Powder Cost Drivers
10
• Powder chemistry requirements
- Custom alloys (first pound is a killer)
- Sourcing restriction (domestic vs. foreign)
- Overly tight controls

12. Metal Powder Cost Drivers
11
• Powder chemistry requirements
- Custom alloys (first pound is a killer)
- Sourcing restriction (domestic vs. foreign)
- Overly tight controls
We need oxygen
between 0.145% &
0.150%

13. Metal Powder Cost Drivers – PSD
12

14. Metal Powder Cost Drivers – PSD
13

15. Metal Powder Cost Drivers – PSD
14
Surface Enh.
AdditiveMfg.
MIM

16. Metal Powder Cost Drivers – PSD
15
L-PBF Spec Size Range
(microns)
Company A -45 mm
Company B 10 - 45 mm
Company C 15 - 45 mm
Company D -53 mm
Company E 10 - 53 mm
Company F 15 - 53 mm
Company G 20 - 63 mm
Company H 25 - 63 mm
Company I <5 mm

17. Metal Powder Cost Drivers – PSD
16
L-PBF Spec Size Range
(microns)
Company A -45 mm
Company B 10 - 45 mm
Company C 15 - 45 mm
Company D -53 mm
Company E 10 - 53 mm
Company F 15 - 53 mm
Company G 20 - 63 mm
Company H 25 - 63 mm
Company I <5 mm
A typical human hair is 100 mm!

18. We are working hard to harmonize PSDs
17

19. PSD Games That We Must Play
18
0 500 mm
Ideal World
Laser Ebeam HIP
53 106

20. PSD Games That We Must Play
19
500 mm
Harsh Reality
Laser Ebeam HIP
45, 50, 53, 630, 10, 15,
20, 25

21. Metal Powder Cost Drivers
21
Overly tight PSD requirements
Powder 1 Powder 2
PSD
d10 = 10-12 mm
d50 = 16-20 mm
d90 = 44-47 mm
15-53 mm, 5%
tolerance
Cost 1.4X X

22. Why use Additive
22
• Print geometries that improve osteointegration
• Control mechanical properties – minimize stress shielding
• Patient-specific implants

23. And along comes additive …
23

24. And along comes additive …
24
Contrary to what many are saying …
AM is NOT always the best tool for the job.

25. Give me a ring with any questions
– Eric Bono
– Carpenter Technology Corp.
– Phone: 412.260.8048
– Email: ebono@cartech.com
20

26. Biomedical
21st CENTURY
ENABLING TECHNOLOGIES
Properties and Applications of PEKK in Orthopaedics
OMTEC
June 13, 2018
OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
Oxford Performance
Materials
Scott DeFelice
Chairman and CEO
Oxford Performance Materials

27. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
What is PEKK?
High Performance
• Medical
• Aerospace
• Defense
• High Temperature Industrial
• Oil Field/Down Hole
• High Performance Automotive
Engineering
• Sporting Goods
• Orthotic/Prosthetic
• General Industrial
• Lawn & Garden
Commodity
• Infrastructure
• Packaging
• Increasing
Temperature,
Tolerance, &
Physical
Performance
OPM’s OXPEKK® formulation
has exceptional physical
properties:
• Superior strength
• Excellent chemical
resistance
• Tailored electrical
properties
• -300°F to 300°F
applications
PEKK
2

28. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
3
• PEKK polymer is shown to be safe for long term human
implantation in sites with primary bone/tissue contact
• Extensive testing in accordance with ISO 10993 standards
Genotoxicity
(ISO 10993-3)
Cytotoxicity &
Neurotoxicity
(ISO 10993-5)
Implantation
(ISO 10993-6)
Irritation and
Sensitization
(ISO 10993-10)
Systemic Toxicity
(ISO 10993-11)
Chemical
Characterization
(ISO 10993-18)

29. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
4
PEEK PEKK
Superior Fiber Adhesion Enables Superior Performance
PEKK vs. PEEK
Thermal:
• Higher glass transition
Co-Polymer System:
• Variable isomer ratio
(T/I, 60/40 or 80/20)
• Control of kinetics
Mechanical:
• Substantially higher compressive
strength & increases in most
other properties
Lower Molded In Stress:
• Concentricity
• Flatness
Kinetics:
• Slower crystallization kinetics
leads to lower molded In stress
• Reduces the need for secondary
annealing operations
Non Sodium Based Catalyst:
• Low ionic extractable
content (high purity)
Adhesion:
• Superior adhesion performance
Adhesion & Wetting
• PEKK chemistry highly suitable for
bonding
• Ability to adhere to itself
• Enabling mechanical performance

30. 3D Printed PEKK Counters Antibiotics Abuse/Overuse
OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
5

31. Osseointegration
In an ovine model, histological review of TETRAfuse™ 3D Technology samples showed deeper implant
osseointegration and more notable trabecular bone ingrowth (Table 1) compared to PEEK and titanium (Ti)
coated PEEK.2
TABLE 1: Results from TETRAfuse Ovine Study
TETRAfuse is the trademark of RTI Surgical, Inc. for its use of OPM’s OsteoFab® Technology. All data above are the property of RTI Surgical, Inc.
OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
6

32. OsteoFab® 3D Printed Medical Devices
“Debulking” of implant
from powder bed
OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
Selective laser
sintering
Multiple units processed
in one build
Digital build preparation
Dimensional
and visual
inspection
Shipment
to
healthcare
facility
Implantation
7

33. 8
Titanium
✓ Complex designs
✓ Biologic fixation
✓ Radiolucency
✓ Bone-like mechanics
PEEK
OsteoFab®
Technology
✓ Bone-like mechanics
✓ Radiolucency
✓ Biologic fixation
✓ Antibacterial properties
And with Additive Manufacturing:
✓ Reduced Cost
✓ Manufacturing flexibility
✓ Complexity - new solutions
OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
PEKK: The Perfect Combination For Implantation

34. Case Study: Right Frontal Sphenoid Parietal Orbital Implant
Hôpital Notre-Dame, Montreal, Québec, Canada
OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
9

35. Disruptive Attributes
3D Printed PEKK Technology: Disruptive in Medicine
OsteoFab®
Technology
Fixation
by Bone
Imaging
Friendly
Promotes
Bone
Formation
Infection
Resistant
Durable
Biocompatible
Precise
Fit
Load
bearing
Material and Manufacture
• Low cost + complexity
Enables New Functionality
• Bone ingrowth
• Tx Delivery
Changes Treatment Approach
• Elevated response
• New devices
Streamlined Development
• Regulatory framework
10
OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL

36. OXFORD PERFORMANCE MATERIALS, INC – PROPRIETARY AND CONFIDENTIAL
Cranial
Facial
Ligament Repair
Shoulder Reconstruction
Spine
Cardiothoracic
Reconstruction
Knee Infection
Knee Replacement
Osteotomy Wedge
Small bones
Foot
Small bones
Hand
Ankle Reconstruction
Long Bone
Defects
Mandibular Reconstruction
Certain devices and
concepts above are under
development and have not
been cleared by the FDA
OsteoFab® Technology Platform Going Forward:
A Platform for Accelerated Device Development
11