Founder and CEO Jason Haider highlights the company’s new biomimetic implant as well as the materials science behind Xenco Medical’s disposable surgical systems.
Below is an interview that Brian Fitzgerald conducted with Xenco Medical Founder and CEO Jason Haider. He discusses Biomimicry in surgical implants through materials science.
In a 2018 article by researchers at The Centre for Nature Inspired Engineering at University College London entitled “Re-designing materials for biomedical applications: from biomimicry to nature-inspired chemical engineering”, the researchers noted that “there has been increased interest within the scientific community in redesigning materials and processes, based on biological or other natural analogies. These studies belong to three distinct categories, based on how the natural component is used: (i) nature-inspired, (ii) nature-mimicking or (iii) nature-integrated design.” Making efforts to harness the elegant designs in nature while developing biomedical devices that work in harmony with the body, researchers have paid increasing attention to patterns in the natural world as sources of inspiration. The translation of these efforts to actual applications in the realm of surgery, however, requires many more barriers and, as a result, has been rather rare. It’s in this context that medical device manufacturer Xenco Medical has leveraged its materials science-driven approach to surgical system development to tackle the challenge of achieving biomimesis in spinal implants while offering a single-use instrument framework. The company, known to many for its development of composite polymer spinal systems that are disposable and injection-molded yet as strong as metal, has expanded its materials science focus to include biomimetic titanium foam implants. I spoke with Xenco Medical Founder and CEO Jason Haider to learn about his company’s new biomimetic implant as well as the materials science behind Xenco Medical’s disposable surgical systems as a whole.
Because of their ability to withstand force while offering biocompatibility, metals such as titanium have been used in surgical applications for some time now. I asked Jason Haider about how Xenco Medical approached the challenge associated with the high-density and non-elastic nature of titanium compared to human bone. “You’re right that the mechanical profile of traditional titanium implants, specifically its compressive strength, has been prohibitive and has called for deeper, more meaningful innovation to achieve true bone-like properties. In order to address this, we chose to mimic cancellous bone in structure while harnessing the low electrical conductivity benefits of titanium. We leveraged advanced, materials science-driven manufacturing techniques that allow titanium and thermoplastic binders to work in concert,” notes Haider. He continued by noting that this combination of materials in the manufacturing process allows Xenco Medical’s nature-inspire implants to be made of titanium foam, which offers a unique structural advantage. Haider notes, “by incorporating multiple materials in the production process, the result is a remarkably energy-absorptive implant with interconnected pores that permeate our titanium foam implants and produce capillary action throughout their structures.” The capillary action Haider mentions is a biomimetic feature that should dramatically facilitate bone ingrowth by allowing bone to not only adhere to the surface of each implant but travel throughout the entire implant, effectively incorporating the implant into the spine during the healing process.
The capillary effect occurs when the forces of adhesion are stronger than the forces of gravity and cohesion, and the liquid molecules adhere to the porous tunnels inside each nature-mimicking implant. In an attempt to establish a steady state between the forces of cohesion and adhesion, the cohesive forces of the liquid molecules attempt to reduce the surface attention, and, as a result, force the liquid molecules to climb up the titanium foam, against the force of gravity. “Beyond promoting vascularization, the materials-science driven manufacturing process for each titanium foam implant achieves the optimal modulus of elasticity one would expect from a device modeled after cancellous bone,” notes Haider. This bone-like modulus of elasticity has important surgical implications according to a study by the Department of Neurological Surgery at Rutgers New Jersey Medical School entitled “Elastic Modulus in the Selection of Interbody Implants.” The study notes that implants that are not similar in their modulus of elasticity to native bone can result in surgical complications over time. As the study puts it, “modulus mismatches may be responsible for the late complications which are observed to occur following ACDF surgery. Conditions which may arise, in the later postoperative period, following anterior cervical decompression and fusion (ACDF) surgery are: non-union or pseudoarthrosis, adjacent segment disease, and strut subsidence.” The study also notes that “implants with stiffness much greater than that of surrounding bone, such as those made of metals, have been shown to cause acceleration of the degenerative process.”
Above: The titanium foam that comprises Xenco Medical’s spinal implant performs like a metallic sponge and is pre-attached to the company’s disposable instruments.
Introducing surgical products manufactured through the use of multiple materials is not new to Xenco Medical. The company’s rapid nationwide growth has been spurred by the fact that its surgical instruments are each made from a composite material that surgeons can dispose of after each surgery. I asked Haider to explain some of the materials science behind the company’s breakthrough instruments as well. Haider notes, “ each Xenco Medical instrument is the product of aligned and randomly oriented fibers working cohesively with semi-crystalline nylon to produce instruments with high interfacial bonding to transmit applied stress from the matrix phase to the dispersed phase, allowing for a remarkably high strength-to-weight ratio.”
As the tissue engineering scaffold industry continues to evolve, the growing number of degenerative spinal surgery cases, due to an aging population, has undoubtedly accelerated the pace of innovation in this space in order to meet the growing demand of those in need of restoring their mobility. Load-bearable scaffolds, in particular, have been a sector with pronounced innovation. The rewards for biomimetic optimization of both biocompatibility and elasticity in a sponge-like titanium implant seem too intriguing to ignore and will likely spur others to try and emulate Xenco Medical’s technology within this single-use instrument framework. As advancements in spinal implants continue to transform the surgical landscape, it will pay dividends to monitor how other companies adjust their research and development efforts.
On the verge of a green and clean era in the metal tool industry.
Expensive metalworking fluids may no longer be needed to cool and lubricate workpieces and cutting tools. Instead, there is green and clean method, EcoCooling, which uses only ionized and cooled air and has none of the environmental hazards and costs related to oil-based fluids.
EcoCooling is the result of long-term, interdisciplinary R&D from the same team that developed the technology behind Amazon’s ground-breaking family of front-lit Kindle devices. Now the group of scientists, engineers, and experienced businesspeople has developed a dry, clean, and environmentally friendly method to lubricate metal workpieces with ionized and cooled air without using any emulsions.
“Workshops have wanted to get rid of fluids and many have tried to find a solution to the problem, but with poor results,” says Leo Hatjasalo, co-founder and CEO of EcoCooling. “Now we have the answer to this demand, since EcoCooling can be used even with the hardest known metals like chrome, titanium and tungsten carbides.”
Market outlook The global market value for metalworking fluids is estimated at approximately $12 billion this year, with estimates for the global market value for machine tools expected to grow from $ 120 billion to $ 150 billion in five years’ time. The growth is driven, for example by the accelerating need for components in the aerospace, automotive and transport sectors.
“EcoCooling is based on the fact that ionized air penetrates the cutting zone and forms a dry lubricant that decreases cutting friction and generated heat, at the same time speeding up the oxide layer formation,” Hatjasalo explains. “The process is patented on all continents, and at the moment we are validating it to include all types of machine tools.”
Hatjasalo emphasizes that EcoCooling is not only a way to cut down the costs of emulsions, but also a way to improve productivity through higher cutting speed, reduced wear of cutting tools and minimized maintenance costs.
“Since the metal chips are not contaminated by any fluids, they can also be fully recycled without cleaning,” he says. “Another big advantage is that it eliminates toxic fluid waste and fumes, in addition to minimizing CO2 emissions, since no oil is used.”
The technology makes it possible to build smaller and cheaper metalworking machines, since the EcoCooling unit is very compact in size.
“The unit does not need any service and it has proved to prolong the lifetime of the cutting tools significantly,” Hatjasalo says. “The system can also be easily retrofitted to older machine tools.”
During the past few years, EcoCooling has been successfully trialed in numerous commercial tests in demanding surroundings internationally. Now that the process has proved to give excellent results, big savings and substantially less environmental impact, the aim is to create a versatile EcoCooling product family that includes all machine tools in addition to just turning machines.
“We are also planning to integrate the system to suit different CNC machine tools and to create optimal solutions for all machine tools and workshop environments”, Hatjasalo says. “Therefore, the next step is to find an industrial partner to help us to commercialize EcoCooling globally and to develop the ways the technology can be used.”
Robotics and automation from Germany cannot escape from the economic consequences of the corona crisis.
The outlook for 2020, given before the outbreak of the pandemic, is likely to weaken considerably – VDMA R+A is currently expecting a drop in sales of at least 20%. Originally, a decline of -10% had been predicted. In contrast, the fundamental growth prospects of the industry are positive for the time after COVID-19.
"The current uncertainties do not allow for a precise forecast for the current year," says Wilfried Eberhardt, chairman of VDMA Robotics + Automation. "However, the industry's turnover before the outbreak of the pandemic was better than initially assumed, as the annual statistics for 2019 show. Robotics and automation from Germany recorded the second-highest turnover to date, at 14.7 billion euros, with a slight decline of 2% compared to the previous year. Originally, a -5% had been forecast."
The three sub-sectors in comparison The sub-sectors of robotics and automation developed differently in 2019: integrated assembly solutions recorded a 4% drop in sales to 8 billion euros. Sales in robotics fell only slightly by 2% to 4 billion euros. Machine vision, on the other hand, was able to grow slightly: Industry sales rose by 1% to 2.8 billion euros.
New tasks for robotics and automation As a result of the Corona pandemic, robotics and automation has faced new challenges: The companies are delivering numerous new solutions in the fight against COVID-19 in record time, and very flexible production lines have been set up for the mass production of respiratory masks and laboratory products. Vaccine development and mass testing benefit from the advances in lab automation. Disinfection robots are used in hospitals. Even communication robots are making their contribution by virtually bringing family visits to nursing homes where visits are currently restricted. "Robotics and automation have responded to the Corona challenge with great commitment and creativity and impressively demonstrated how flexibly the technology can be used," says Patrick Schwarzkopf, managing director of VDMA Robotics + Automation.
Robots are immune New rules for infection protection require minimum distances between people – also in manufacturing. This is where robots or automated process steps are helpful in organizing the production floor. Collaborative robots (cobots) that work directly with humans can demonstrate their strengths here. They assist humans at close range without any risk of infection. Robotics thus contributes to safe and flexible production. In addition, the increase in shopping online makes the use of robots in logistics increasingly attractive.
Digitalization boost The corona pandemic will prove to be a veritable accelerator of digitalization. As in the office environment, new technologies must be introduced quickly in production - for example, for remote maintenance and virtual commissioning of complex systems. "Digital services, which were already available before the Corona crisis, have suddenly become indispensable and put users and providers on a steep learning curve. This advances the smart factory and provides robotics and automation with an important long-term growth incentive," Eberhardt says.
New potentials after COVID-19 The Corona crisis has highlighted how vulnerable industrial production has become in global value chains. The realization that more resilience is required opens up new potentials for robotics and automation. Supply chains are being rethought and the manufacture of critical parts and products will be done more locally - and with an increased share of internally produced components. This can only be implemented economically with a higher degree of automation. New production technology is also needed for attaining higher levels of sustainability, carbon neutrality and alternative powertrains for future mobility. There are also considerable catch-up effects from previously postponed investments. All of these factors will fuel demand in robotics and automation in the post-Corona era and thus offer the industry excellent prospects for the future.
Leading event in December Robotics and Automation is particularly looking forward to the leading trade fair automatica, which will take place in Munich from December 8-11, 2020.
With the lead theme Industrial Transformation, Hannover Messe spotlights all of the latest topics in industry, including Industrie 4.0, artificial intelligence, 5G, and smart logistics.
As COVID-19 continues to cancel in-person events, and as the European Union is considering a ban on allowing American's to travel to Europe - the U.S. is struggling to contain cases of the coronavirus and 23 states are seeing massive increases in cases - you won't have to miss Hannover Messe. The event - cancelled in April - is being held digitally for 2 days in July and registration is free. You don't have to pay airfare or lodging as you can participate and view the sessions you want directly on your computer. Here's what's planned for the event next month. Please, stay safe, wear a mask, and remain socially distant so we can avoid a resurgence of COVID-19.
The Hannover Messe Digital Days launch on July 14, 2020, with a diverse, top-class program. The event begins with the panel discussion "Forward to the New ‒ New Opportunities for Progress?" featuring Siemens board member Klaus Helmrich; Festo chairman Oliver Jung; BDI president Dieter Kempf; Friedhelm Loh Group owner and chairman Friedhelm Loh; Robert Bosch managing director Rolf Najork; and SAP board member Thomas Saueressig.
It continues with exciting keynotes, panel discussions, live chats, networking, and innovation presentations that cover current developments in the fields of industry, energy and logistics. The premium partners ‒ Beckhoff, Cisco, Festo, Harting, Ifm, Igus, Phoenix Contact, Rittal, Schneider Electric, and Siemens ‒ present their products and solutions in separate live sessions. The Digital Days feature four tracks on both days. In one of these virtual rooms, Sabine Bendiek, CEO of Microsoft Germany, kicks off the WomenPower congress with a keynote. In the afternoon, one of three nominees will be announced Engineer Powerwoman 2020.
The Hermes Award presentation marks a further highlight on the first day of the conference. The three nominees are the Friedhelm Loh Group, Schneider Electric and Trumpf. Professor Reimund Neugebauer, president of the Fraunhofer-Gesellschaft and jury chair, announces the winner of the coveted technology prize on July 14. The ceremony includes the premier of the HERMES Startup Award.
Professor Thomas Wimmer, CEO of the German Logistics Association, moderates the logistics session about innovation and resilience of global value chains in agricultural machinery production. His guest is Josip T. Tomasevic, senior vice president and chief procurement officer at AGCO Corporation, Duluth, Georgia, USA.
Partner Country Indonesia starts the second conference day with Arif Havas Oegroseno, Ambassador of the Republic of Indonesia to the Federal Republic of Germany, providing an overview of Indonesia's economic development and investment opportunities for industry.
Another highlight is EU Commissioner Thierry Breton's panel discussion about EU policy after Corona. Participants include Antonio Krüger, managing director of the German Research Center for Artificial Intelligence (DFKI); Björn Rosengren, CEO of ABB; and Jean-Pascal Tricoire, CEO of Schneider Electric.
Thematically, the Hannover Messe Digital Days focus on the content of the trade fair. The conference program covers topics such as Industrie 4.0, artificial intelligence, smart energy, and Logistics 4.0. Exhibitor product and solution presentations form the second pillar of content. The networking component enables all participants to search for suitable business and cooperation partners and make contact directly via the chat function. Participation is free. More information is available at https://hannovermesse.digital.
Hannover Messe Digital Days Hannover Messe is the world's leading trade fair for industrial technology. With the lead theme Industrial Transformation, it spotlights all of the latest topics in industry, including Industrie 4.0, artificial intelligence, 5G, and smart logistics. Hannover Messe is expanding its portfolio this year with a digital event, Hannover Messe Digital Days, which premieres from July 14-15, 2020.
JMPP, the Reshoring Initiative analyze the COVID-19 crisis.
COVID-19 has exposed how many domestic brands rely significantly upon China for fulfilling some, part, or nearly all of their supply chain.
The Reshoring Initiative (RI) founder and president Harry Moser and JM Performance Products (JMPP) president John Stoneback participate in a Q&A on how the crisis has affected the reshoring effort.
Moser: The annual rate of jobs coming from offshore increased from 6,000 in 2010 to 180,000 in 2017. The cumulative jobs brought back represent about 5% of total U.S. manufacturing employment as of Dec. 31, 2019. The annual rate moderated in 2018-19, mainly because of President Donald Trump’s tariffs, which caused business uncertainty.
Multi-step, multi-country manufacturing was under stress even before the COVID-19 pandemic, which has severely disrupted the global logistics network. Our understanding of trade wars during this crisis now reveals the supply chain weakness – we simply don’t make enough components on our own shores.
Stoneback: As manufacturing reshores and jobs open up, the need for skilled operators will increase. Manufacturers will be faced with elevated costs as they hire skilled workers, invest in training, or define new methods so that lesser skilled employees are able to handle the production requirements.
Companies that examine their operations at the machine shop level and take action to correct problems at the very base will be able to forego the highly skilled individual, instead opting to employ a less skilled individual who will not need to make on-the-fly adjustments.
How is the COVID-19 crisis different than others like 9/11 or the 2008 recession in terms of reshoring and manufacturing?
Moser: On the international market, import and export regulations can always be a hurdle for finding the right suppliers. This was especially true for US businesses after 9/11. The extra time and money spent on certifying a supplier for regulations like the Customs Trade Partnership Against Terrorism (C-TPAT) is another trade-off that management must consider when diversifying their supply chain.
The financial crisis of 2008 drove OEMs to essentially not buy anything. On-hand plus pipeline inventory from Chinese suppliers might total 3 to 6 months usage – if you get it locally, it’s 3 to 6 weeks. Additionally, big companies are more resistant to recession and can handle the problem of low sales much better. China pays in advance and the U.S. pays 60 to 90 days after shipment, so there’s more control during a disaster.
Developing domestic partnerships is the new reshoring. Customers, in most cases, are willing to pay a premium for on-time, as-promised delivery commitments. The goal is to convince companies to do the math and decide what to reshore now.
Stoneback: This crisis has made the entire country aware of our supply chain issues. Many consumers were blissfully unaware that our nation is dependent upon China and other Eastern countries for so many commodities such as pharmaceuticals, textiles, medical devices, and even food. Our lack of preparedness and inability to secure life-saving equipment and supplies opened many eyes. In past crises, the supply chain was not as critically impacted. The general population is now calling for reform, and it is up to North American manufacturers to reduce the risks of a broken supply.
Can COVID-19 be a positive/progressive factor for reshoring?
Moser: This can become a real opportunity to drive publicity about reshoring. It reminds me of an infamous quote from former Chicago mayor and chief of staff Rahm Emanuel to President Barack Obama during the 2008 financial collapse: “Never allow a crisis to go to waste…start planning for the future.”
Stoneback: This situation provides the catalyst for manufacturers to reexamine how they buy and how they manufacture. There is an imminent demand emanating from the consumer level to make changes. A new understanding that the least expensive supply or manufacturing options may ultimately bare the highest risks will add a new dimension to cost analysis. There will hopefully be a migration at the consumer level from purchasing the least expensive articles to purchasing fewer items, but those that are domestically manufactured and better quality.
Which markets/industries are most susceptible to COVID-19 and would benefit most from reshoring?
Moser: Shortages of medical products due to 90% to 95% dependence on imports make medical and pharmaceutical markets the top priority targets which bridge over to OEMs for components. Medical supplies accounted for roughly $53 billion worth of U.S. imports last year. Reshoring production for half of those supplies could generate an additional 302,000 jobs and add $534 billion to the GDP.
When the COVID-19 pandemic ends, America’s global supply chain must be replaced with local and national sourcing, but it won’t just be in health care. Other leading industries of focus include transportation equipment, appliances, plastic and rubber products, fabricated metal products, electronics, and apparel.
Stoneback: The mold making industry in this country undeniably took a heavy hit due to off-shoring production. Reshoring would allow for higher quality, longer life, and faster response to opportunities. Having the ability to reduce costs in mold production, along with the reduction of transportation costs, would put mold makers in a stronger, more sustainable competitive position.
What opportunities/pitfalls does this represent for domestic manufacturers?
Moser: COVID-19 is a valuable wake-up call as it reveals our weaknesses and what we can, and need, to do. There’s substantial interest from the administration to build up US manufacturing, so we need to push for more funding for proactive organizations and programs that are in place that can help in the process of reshoring. Notably, Manufacturing Extension Partnerships (MEP) and the Coronavirus Aid, Relief, and Economic Security (CARES) Act are vital programs that can help manufacturers select the US now in focusing on reshoring.
How can domestic manufacturers offset costs vs. offshoring post COVID-19?
Moser: The key is to calculate and measure costs correctly. Take a look at key reshoring factors like duty freight, the cost of inventory, travel, etc., and how that impacts total costs and factor that in. Then, you can also factor in reshoring savings like Trump tariffs as well as cost savings from state-side technology production efficiencies like JMPP’s HTRKs that can drive those numbers higher.
Stoneback: Fewer interruptions to the process yields high production and lower costs. Reduction in secondary or additional processes not only positively impacts the cost per unit, but also impacts the cost associated with handling the product multiple times. Any reduction in production cost impacts the manufacturer’s competitive edge.
How does COVID-19 affect the global supply chain landscape?
Moser: Having relegated the supply chain to China for most of the past decade, some companies started taking steps last year to divest their over-reliance on Chinese parts, prompted by the trade war. Some companies shifted low-cost parts acquisition to Vietnam and others to Mexico.
Trade as a percentage of world Gross Domestic Product (GDP) over the last 3-4 years was slowing and already plateauing before COVID-19. Companies were beginning to realize that depending on other countries wasn’t the economic or ‘green’ solution long term. So, the focus was trending towards localization/regionalization even before the global pandemic.
According to our Reshoring Initiative study, manufacturing jobs via reshoring by U.S. companies and through foreign direct investment (FDI) grew to 180,000 in 2017, the fastest rate in history. That’s up 50% from 2016 and 2,800% from 2010. This must continue in the post COVID-19 economic landscape, and the US should leverage more outsourcing from Mexico versus China if the US isn’t an option.
Will this crisis shift/influence the higher cost vs. lower risk equation of reshoring?
Moser: When people reshore, they accept a higher US cost, but reduction in overhead (inventory, travel, international property, etc.). The bottom line is to reshore the products where the savings on overhead and risk is greater than the increase in manufacturing cost.
Stoneback: Effectively reducing the manufacturing costs, along with reduction in overhead costs, will ultimately lower the higher costs people have to accept.