Mighty Oak Medical, a medical device development company that specialises in creating and commercialising spinal technologies, 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.

Mighty Oak’s FIREFLY solution aims to increase 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, making spinal surgeries more successful and less stressful. 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.

Heidi Frey, president at Mighty Oak Medical, said: “It was important for us to maintain our focus on the spine and develop innovative solutions that make surgical procedures safer and more efficient. 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.”

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 says it is experiencing unprecedented efficiencies -- all while improving replicability and consistency in pedicle screw placement and achieving 99.7% screw placement accuracy. These patient-specific guides eliminate intra-operative radiation exposure for both surgical staff and patients, and the maintenance and technician costs associated with other solutions.

Greg Elfering, head of Americas Go-to-Market, HP Personalisation & 3D Printing, said: “Mighty Oak is currently leading the charge towards a more advanced medical device and orthopaedic industry with its FIREFLY solution. “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.”