Mighty Oak Medical collabs with HP for 3D printed healthcare applications

Mighty Oak Medical, a medical device development company that specialises in creating and commercialising spinal technologies, has announced a technical partnership with HP for 3D printed healthcare applications produced using HPs Jet Fusion 5200 3D printers.

Applications currently being manufactured include Mighty Oak’s cornerstone product FIREFLY, a patient-specific pre-surgical planning and navigation platform. Mighty Oak has achieved FDA clearance and CE-mark for FIREFLY’s 3D printed medical models and 3D printed surgical guides to deliver incredible value for patients, surgeons, and the healthcare system.

Mighty Oak Medical’s FIREFLY solution increases precision and safety, while reducing efficiency challenges common in spinal fusion surgery, by providing surgeons with accuracy to-the-millimetre concierge pre-surgical planning done in 3D on virtual renderings of patients’ spines. 3D printed anatomical models and disposable guides are then used by surgeons to drill, tap, and place pedicle screws quickly and safely. Now, with HP’s industrial Multi Jet Fusion technology, FIREFLY is streamlining and reducing printing turnaround time, meaning even more patients can benefit from an elevated level of personalised care.

“It was important for us to maintain our focus on the spine and develop innovative solutions that make surgical procedures safer and more efficient,” said Heidi Frey, president at Mighty Oak Medical. “We have always viewed 3D printed, patient-specific solutions as an ideal way to achieve those two objectives, and now, thanks to HP’s 3D printing technology, the healthcare industry is undergoing a massive transformation in terms of the solutions, patient experience and outcomes new 3D printed medical devices can provide.”

With an eleven-year history of applying additive manufacturing technologies to enhance and produce spinal technologies and medical devices, Mighty Oak Medical is no stranger to the benefits of 3D printing or the pain points associated with spinal surgeries. Spinal fusions, a typical treatment option for fractures, deformities, or instability in the spine, typically involve the use of pedicle screws to provide extra strength and support. However, if placed incorrectly, patients could experience critical injuries including damage to the spinal cord. While robotic solutions exist to alleviate the errors associated with freehand pedicle screw insertion, this technology is expensive and has a steep learning curve to its use. Mighty Oak’s familiarity with 3D printing technology resulted in the FIREFLY complete navigation system for streamlining the surgeon’s workflow and reducing screw placement time.

Since installing HP’s Jet Fusion 5200 printers directly onto its factory floor, Mighty Oak Medical is experiencing "unprecedented efficiencies" -- all while improving replicability and consistency in pedicle screw placement and achieving 99.7% screw placement accuracy. These hyper-personalised patient-specific guides eliminate intra-operative radiation exposure for both surgical staff and patients, and the maintenance and technician costs associated with other solutions. HP’s 3D High Reusability PA 12 material offers excellent strength, detail, and surface finish with higher contrast, allowing surgeons to check for anomalies and gaps as well as read markings easier in an OR environment.

“Mighty Oak is currently leading the charge towards a more advanced medical device and orthopaedic industry with its FIREFLY solution,” said Greg Elfering, head of Americas Go-to-Market, HP Personalization & 3D Printing. “We are excited to partner with Mighty Oak to maximise the benefits of HP’s 3D printing solutions for healthcare applications. By minimising costs, enabling personalisation, and improving efficiency and accuracy of care for patients, Mighty Oak and HP are demonstrating how the power of innovation can positively impact patients and the healthcare industry.”