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Additive or Subtractive? Matching Implants to Manufacturing Technology

When: Thursday, June 13 | 10:00 am - 11:00 am 
Where: Room 49 - Product Lifecycle Management Track | 
Level: Intermediate, Advanced
Participant Type: Research & Development, Product Development, Regulatory/Clinical Affairs, Quality Control, Manufacturing



Additive manufacturing is today’s “hot topic” in orthopedics. 
In this round table, additive veterans cut through the hype and focus on the practical and profitable applications of the technology. They urge that it should not be used for the design and manufacture of every device. Rather, additive manufacturing is a fit when used for complex designs and cost savings. Technology pioneers along with OEM, contract manufacturer and equipment supplier perspectives ensure that attendees are educated and empowered with the knowledge to optimally leverage its advancements.


  • Understand the factors to consider for use of additive vs. subtractive manufacturing
  • Learn the best applications for additive manufacturing in orthopedics
  • Gain insight for additive manufacturing use from OEM, contract manufacturer and equipment company perspectives


Andy Christensen’s entire career has focused on developing and expanding the medical applications of 3D printing/additive manufacturing.
His introduction to 3D printing was through the stereolithography process in 1993. Shortly thereafter, he began to work with surgeons to facilitate better surgical planning through use of these technologies. From 2000 to 2014, he was the Founder and President of Medical Modeling, a medical device-focused 3D printing service bureau, which was acquired by 3D Systems. Today, Andy holds the position of Adjunct Professor/Research Associate in the Department of Radiology at the University of Ottawa in Ontario, Canada. In November 2018, he was elected to the Executive Committee of the Radiological Society of North America 3D Printing Special Interest Group. He is also an Associate Editor for the clinical journal 3D Printing in Medicine, published by BMC.

Dillan Drake is an Additive Manufacturing Consultant for Additive Minds, EOS North America.
In this role, Mr. Drake guides organizations through the process of integrating additive manufacturing technology into their current operations. He brings years of experience working in, and alongside, major organizations and government agencies across a range of industries, including automotive, healthcare and aerospace. Mr. Drake joined EOS earlier this year, working out of the company’s global operations, EOS GmbH. Prior to EOS, he held several positions at 3D Systems, managing their first metal additive production and prototyping facility in the United States. He was also the additive manufacturing lead at Stryker Corporation. Mr. Drake is earning his bachelor’s degree in Business Administration from Southwestern University in 2020. He is based in Austin, Texas.

Chuck Hansford, Director of Advanced Materials Processing with Tecomet, oversees all additive manufacturing, R&D and production at multiple Tecomet sites.
He joined Tecomet in 2017 with 35 years of product development experience and 26 years of additive manufacturing experience (plastic & metal). Previously, he was a Senior Manager of Prototype Development with Ethicon Endo-Surgery (J&J), before moving on to Morris Technologies as Vice President of Medical, responsible for all subtractive and additive manufacturing business. While at Morris, his team was responsible for the development of the first two FDA 510(k) cleared additive manufactured implants from DMLS technology. Mr. Hansford is published in several trade magazines and has multiple patents on endoscopic medical devices. He holds multiple bachelor degrees from the University of Cincinnati.

Gordon Hunter, Ph.D. is Principal Manager, Material Science at Smith & Nephew, where he has worked for over 25 years.
He manages standardization of materials and manufacturing processes used for making orthopedic devices and is involved with commercial implementation of new materials and processes. Dr. Hunter led the development and implementation of OXINIUM oxidized zirconium knee and hip prostheses, and continues to coordinate efforts involving that technology. He also works with polyethylene, bone ingrowth surfaces and powder metal technologies. Dr. Hunter graduated from the Massachusetts Institute of Technology with a Ph.D. in Metallurgy and with a SM/SB in Materials Engineering. He received the 2017 ASTM Ogden Award for accomplishments in reactive and refractory alloy technology, and the 2005 ASM Engineering Materials Achievement Award for development of OXINIUM implants. He has 22 US patents and over 50 technical publications.

Gene Kulesha, Senior Director of Advanced Engineering, Onkos Surgical has been involved in medical device technology development for 20 years.
His career started in manufacturing, where he scaled and managed various materials technology production streams. He later transitioned to product development of synthetic bone and allograft implants. Mr. Kulesha's recent responsibilities were in leading the research, development, regulatory clearance and scale-up of various platform technologies used to fabricate advanced implants. He led the teams at Stryker that researched, developed and transferred additive manufacturing technologies, now ubiquitous in their flagship implant lines. Ten product lines were developed and commercialized under his watch. At Onkos Surgical, a company focused on oncology, he leads the anti-microbial and additive manufacturing development programs.


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