New disc prosthesis as a single component from the Modena based company Tsunami Medical. LaserCUSING by Concept Laser, the metal laser melting technique, gave Tsunami Medical the opportuny to develop a customized disc prosthesis that acts as a vertebral spacer to strengthen the spine. It consists of an upper shell and a lower shell connected by a double spring. The shells’ surface is designed to fit perfectly into the vertebral plate. The double spring is made of titanium with a silicone core for damping the movement of the spring. The design and spacing dimensions can be adjusted precisely to the patient’s anatomy in accordance with the surgeon’s specifications. The highlight of this innovative solution: the disc prosthesis is manufactured in a “one-shot” process using laser melting technology, a solution that eliminates the need for downstream assembly processes.
Tsunami’s competencies were put to the test early on. First, it had to translate its experience in spinal implants into a product solution that would increase patient mobility. The disc prosthesis ensures 360-degree freedom of movement, providing enormous support to the patient’s mobility. Optimum elasticity is ensured by the double spring and enhanced through the silicone core. The company also needed a engineering solution that made the most of the geometric possibilities offered by the LaserCUSING method. Stefano Caselli, CEO of Tsunami Medical: “From a design standpoint, the disc prosthesis as a product idea is the direct result of the geometric freedom and functional integration offered by the LaserCUSING method. Conventional manufacturing methods don’t work for this kind of solution. Additive manufacturing complements our expertise in spinal column reconstruction by offering a multitude of new options. The solution is also very flexible: we can adjust the dimensions to a patient’s specific anatomical profile.”