New Breakthrough in 3D-Printed Porous Osseointegration! Croom Medical Launches Biofuse Technology, Applying It to Various Orthopedic Implants

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September 23, 2025 Applications 316

Croom Medical's Biofuse technology enables OEMs to 3D-print lattice structures directly into orthopedic implants, ensuring full compliance with ASTM F1854 standards.

Unicompartmental Knee Prosthesis Diagram

Irish orthopedic device manufacturer Croom Medical has introduced a 3D-printed porous osseointegration technology named Biofuse, specifically designed for orthopedic implant production. Developed based on laser powder bed fusion additive manufacturing process, this technology enables original equipment manufacturers (OEMs) to directly integrate lattice structures into the geometry of implants, fully complying with ASTM F1854 standards.

Croom Medical states: "By integrating solid and porous structures in a single manufacturing process, Biofuse enables implants to achieve both mechanical strength and efficient osseointegration, providing solutions for diverse orthopedic applications."

Precision Lattice Design: The Foundation of Osseointegration

Croom Medical highlights that its Biofuse platform utilizes lattice engineering to precisely control key implant characteristics—including pore size, porosity, and coefficient of friction—enabling customized designs that meet both mechanical and biological integration requirements.

According to Croom Medical, a higher coefficient of friction improves initial implant stability by enhancing contact with surrounding bone. An interconnected porous structure, with porosity adjustable between 50% and 80%, balances stiffness and fluid permeability, creating favorable conditions for angiogenesis and osseointegration. A pore size range of 100–600 micrometers supports tissue integration and nutrient transport while maintaining structural integrity.

The company also notes that Biofuse allows solid and lattice regions to be produced in a single printing process, with selective application of lattice structures even in complex or constrained areas. This capability helps OEMs replicate existing implant designs or develop new structures that enhance fixation and manufacturability.

Applications and Industry Value

Croom Medical reveals that Biofuse technology has already been applied in producing various orthopedic implants, such as unicompartmental knee prostheses, spinal cages, acetabular cups, femoral components for total knee arthroplasty, and revision cones. Collaboration with industry partners and ongoing advancements in powder bed fusion technology ensure that lattice-structured implants meet both mechanical performance and regulatory standards.

Femoral Component Diagram

3D Printing: Reshaping the Landscape of Orthopedic Medicine

Beyond Biofuse technology, 3D printing continues to drive transformation in the orthopedic medical field. In June 2025, 3D-printed orthosis provider Dimension Ortho partnered with Rothman Orthopaedics, a leading U.S. orthopedic institution renowned for its achievements in musculoskeletal medicine. This collaboration will enable Rothman Orthopaedics to integrate Dimension Ortho's customized brace and fracture care platform across its clinical network, aiming to elevate patient care standards.

In March 2025, the medical division of incotek obtained a patent (Patent No.: US 12,171,464 B2) for a 3D-printed screw designed to enhance osseointegration and provide a higher degree of customization for orthopedic surgeries. Patent documentation indicates that this screw incorporates a lattice structure, allowing its mechanical properties to be tailored to surgical requirements and individual patient anatomy. Compared to traditional bone screws—typically machined from titanium alloy with a solid, smooth surface—this innovative design offers superior adaptability.