MedShape’s 3D printed FastForward Plate

MedShape’s 3D printed FastForward Plate

3D printing with medical grade titanium allows for devices with complex, customizable geometries, such as the FastForward Bone Tether Plate.

February 10, 2015
Manufacturing Group
3D/Additive/Alternative Contract Manufacturing Devices/Implants/Equipment Industry/Regulations Materials People/Facilities Design/Engineering

Atlanta, Georgia – MedShape Inc. officials announced that the company has received U.S. Food and Drug Administration (FDA) 510(k) clearance for its FastForward Bone Tether Plate. The Bone Tether Plate features MedShape's latest technology platform, the 3D printing of medical grade titanium alloy (Ti-6AL-4V) that allows for the fabrication of devices with complex and/or customizable geometries. The plate serves as the primary component in the FastForward bunion correction system, a new approach to surgically correct hallux valgus deformities that preserves and protects the native bone anatomy.

Hallux valgus deformity (or bunion) is a prevalent and debilitating foot condition that affects 23% of people age 18 to 65 each year. Traditional surgical approaches have involved cutting, realigning and fusing the first metatarsal (osteotomy) or fusing the metatarsal-cuneiform joint (Lapidus). However, these procedures are associated with long recovery periods and complications including nonunion, avascular necrosis, and limb shortening. Tethering suture material between the first and second metatarsals has been described as an alternative bone-sparing approach to reduce the deformity. However, peer-reviewed studies have reported the occurrence of second metatarsal fractures due to stress concentrations created by the suture-button implant and the requirement to drill through the second metatarsal.

The FastForward Bone Tether Plate represents a breakthrough in bunion correction by allowing suture tape to be securely and safely wrapped around the second metatarsal eliminating the need to drill through the bone. Thanks to the 3D printing technology, the Bone Tether Plate is equipped with several unique design features including an overall geometry that closely matches the second metatarsal anatomy so that stresses are optimally distributed on the bone and a looped portion that allows suture tape to pass and securely hold the plate in place without the need for bone screws.

In addition, MedShape received 510(k) clearance for its FastForward PEEK Screw System used in conjunction with the Bone Tether Plate to provide fast, reliable fixation of suture tape in the first metatarsal. The entire FastForward Bunion Correction System joins MedShape's growing foot and ankle product portfolio which includes the DynaNail TTC Fusion System and Eclipse Soft Tissue Anchor.

"The FastForward system aligns with MedShape's continued mission to develop and commercialize innovative medical devices from cutting edge materials and manufacturing technologies to address significant clinical needs," said Dr. Ken Gall, chief technology officer of MedShape and professor of Materials Science and Engineering at the Georgia Institute of Technology. "We are in the early stages of tracking clinical outcomes with this new surgical approach and are excited to extend the 3D printing material platform towards the development of other implants."

Source: MedShape Inc.