The term "direct digital manufacturing (DDM)" covers several relatively new manufacturing techniques that build-up 3D plastic or metal parts, layer-by-layer, directly from CAD data. DDM is increasingly big in medical device manufacturing, for instance, in the fabrication of lattice structures. Lattices are engineered to withstand large mechanical stresses while providing a more lightweight part than solid components.

For example, Arcam in Sweden makes so-called e-machines that use an electron beam to melt metal powder layer-by-layer to fabricate physical parts. The technology lends itself well to implant manufacturing, letting users build metal parts with engineered lattices or porosities that facilitate bone ingrowth. With CT scan data as the basis of designs, users build functional custom implants using standard biocompatible metals such as Ti Grade 2 and cobalt chrome that exactly match the shape of a patient’s bones.

German-based EOS also makes DDM machines, but in this case, the machines laser sinter powdered metal or plastic to fabricate parts. Laser sintering is increasingly useful in dental manufacturing. In the past, porcelain-fused-to-metal restorations were made using the traditional lost wax casting process. But the second-operation machining involved in this process is inefficient and costly. Laser sintering lets dental labs fabricate metal copings directly from CAD data, speeding designs and cutting costs. As these technologies continue to advance, more innovation is sure to come.

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