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PhD Position: Design and manufacturing of highly porous and deformable implants

Aarschot, Belgium

The MSCA Project

This Ph.D. position is offered through the Marie Skłodowska-Curie Actions (MSCA) Doctoral Network 'CUSTOM'. Vacancies for other Ph.D. topics within this network can be found on the project's website.

The CUSTOM project unites three core disciplines (design, manufacturing, and testing) towards the development of a next generation of patient-specific shoulder implants. The number of shoulder replacements is projected to increase by 300-400% between 2020 and 2040. With the current technology, 10% of those artificial shoulder implants will fail within the first 10 years of service, mainly due to soft tissue failure, infection, and implant loosening. CUSTOM focuses on combining (1) computational tools that allow patient-specific design, (2) additive manufacturing to realize the custom, complex designs and structures and their further postprocessing to incorporate multi-functionality, and (3) blended in-silico and experimental testing to reduce the burden on experimental testing for certification. In doing so, CUSTOM can address the major failure mechanisms of current shoulder implants and improve their overall functionality and longevity.

The PhD Topic

This project focuses on the development of innovative, highly porous, and deformable implants that represent a transformative step forward in the field of biomedical engineering. These implants, based on a patented concept, are designed to be easily deformed either before or during surgery, allowing them to adapt precisely to a patient’s unique anatomy. This adaptability eliminates the need for custom implants, significantly reducing both time and cost. Utilizing additive manufacturing techniques, specifically Laser Powder Bed Fusion (L-PBF), the implants can be produced in a standardized yet flexible manner, making them a highly promising solution for diverse clinical applications.

The primary objectives of this project are threefold. First, the project aims to investigate and establish a comprehensive digital library of highly porous structural designs. Each design in this library will be characterized by its mechanical properties, making it possible to match implant geometry and function to clinical needs. Second, the project will focus on developing an optimized and cost-effective manufacturing process using L-PBF technology to ensure the reproducibility and scalability of the implants. Third, the project will explore, design, and fabricate specialized deformation tools that can be used to shape the implants as needed during various surgical procedures.

The expected outcomes of this research include: (1) a validated library of porous structures tailored for implant use, with varied mechanical characteristics to support different clinical scenarios; (2) optimized L-PBF parameters that enable reliable fabrication of complex, porous geometries; (3) efficient post-processing techniques that maintain the structural and functional integrity of the implants; and (4) practical deformation methods and tools that surgeons can use to customize implants during operations. This project holds the potential to revolutionize implant design by merging digital design flexibility with advanced manufacturing technologies, ultimately improving patient outcomes and surgical efficiency.

This PhD position is hosted by Amnovis, under the direct supervision of dr. Ruben Wauthle, CEO & Co-founder of Amnovis, and both Prof. Bey Vrancken and Prof. Brecht Van Hooreweder, as part of the Manufacturing and Process Systems division (MaPS) at the Department of Mechanical Engineering, KU Leuven.

Your Tasks

You will work independently on this PhD project, as well as collaborate with fellow researchers in the Amnovis R&D team, the CUSTOM doctoral network, and beyond
Performing tests on our AM machines
Material characterization testing (microscopy, elemental analysis, mechanical testing, etc.) at the internal test lab and in collaboration with external test labs
Analysing and interpreting test results
Detailed and accurate reporting on PhD activities

Your Responsibilities

This PhD is affiliated with KU Leuven and you will be enrolled at the KU Leuven Doctoral School. You must comply with all the requirements of the KU Leuven Doctoral School.
This Ph.D. position is offered through the Marie Skłodowska-Curie Actions (MSCA) Doctoral Network 'CUSTOM'. You must comply with all the requirements of the Doctoral Network.
Obtain your PhD degree
Surveying the state-of-the-art on new technology, process or material developments in the additive manufacturing market, and more specifically within the scope of your PhD topic.

Your Profile

You are a highly motivated, enthusiastic and communicative researcher
You have a MSc in Mechanical Engineering, Materials Engineering, or a closely related field and you obtained your degree with distinction or the equivalent thereof
You have experience with mechanical testing and are familiar with Additive Manufacturing processing conditions, or you are eager to educate yourself on these topics
You have experience with experimental work, and materials characterization techniques (metallography, mechanical testing, ...). Specific experience with metal additive manufacturing is a plus
You have excellent oral and written English communication skills.
Specifically for the MSCA doctoral network, there is a requirement that applicants for this position cannot have resided or carried out their main activity (work, studies, etc.) in Belgium for more than 12 months in the 36 months immediately before their recruitment date. Moreover, applicants cannot have previously obtained a PhD.

Our offer

A doctoral scholarship (fully funded) and a Ph.D. degree in Engineering Science if successful
A highly specialized doctoral training in an international environment at a top European university, as well as through the MSCA doctoral network CUSTOM
Extensive training and networking activities via the MSCA Doctoral Network 'CUSTOM' project, which involves a total of 17 doctoral candidates
The opportunity to perform a PhD at a highly innovative and growing company
A living allowance, mobility allowance and, if applicable, family, long-term leave and special needs allowances
The opportunity to participate in research collaborations and international conferences
No ping-pong or pool tables at Amnovis (yet) ☹️, but we do have darts!
Working location with excellent connectivity to public transportation