About 3D Incredible

3D Incredible (Incredible AM Pvt. Ltd.) is a pioneering medical 3D printing company based in Pune, India, and a subsidiary of Industrial Metal Powders Pvt. Ltd. The company focuses on customized additive manufacturing (AM) solutions for the healthcare sector, offering patient-specific implants (PSIs), surgical guides, and anatomical models for surgical planning.

These implants address complex clinical needs across cranial, orthopaedic, and oral-maxillofacial domains, using biocompatible materials like Ti6Al4V ELI, PEEK, and PMMA. Through digital-to-physical workflow planning, 3D Incredible helps surgeons enhance surgical precision and patient recovery.

Modelling and Implant Design

Design Planning

Defect images are shared with the surgeon via the marketing person. In complex tumour OMF & Ortho cases , a design consultation meeting is held with the surgeon.

Tentative Design

Once approved, a preliminary implant is created using a 3D mirrored model of the healthy bone (via Materialise 3-Matic & Geomagic Freeform). This includes curvature flange locations & temporal cut length and is sent to the surgeon for review.

Final Design

After the surgeon reviews curvature, thickness, temporal cuts, and flanges and osteointegration holes are added. The final version is shared again for approval.

SOFTWARE USED

Materialise 3-Matic

Geomagic Freeform

KEY FEATURES

Customized fit to skull defect

Precise screw fixation points

Tissue Integration

Balanced thickness for durability and lightness

Design Validation

✔ STL files are imported into Materialise Magics.
✔ Wall thickness analysis (ensures strength and printability & Screw hole diameter)
✔ Mesh repair (non-manifold edges, inverted normals)
✔ Labelling
✔ Anatomical fitment check

3D Printing

Final validated STL (Titanium) is printed using Selective Laser Melting (SLM) on the Renishaw AM400 machine.

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Post-Processing & Quality Control

Post-processing steps and quality assurance to ensure surgical suitability and precision.

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Segmentation

Materialise Mimics: Converts medical imaging data (CT/MRI) into accurate 3D anatomical models through advanced segmentation tools.

Design

Materialise 3-Matic: Enables design, editing, and optimization of patient-specific implants based on segmented anatomical models.

Validation

Materialise Magics: Validates, repairs, and prepares implant designs for 3D printing through mesh correction and build optimization tools.

Requirements

✓ High-resolution DICOM data

✓ Input from surgeons regarding screw placements, temporal cuts and material of choice

✓ Compliance with ISO 13485 and US FDA / CE-approved software usage

Design Timelines

CUSTOM IMPLANT DESIGN
PROCESS TYPICALLY

The custom implant design process typically takes 3–5 working days. It starts with data acquisition (0.5–1 day) and segmentation (1 day). Initial design and surgeon review follow, taking 1–2 days. Final design validation is done in a day. 3D printing takes 10–12 hours, and post-processing with quality checks adds 1–2 days.