Adoption of additive manufacturing in orthopedic prosthesis production. An empirical analysis for Italy

This thesis examines how additive manufacturing is transforming orthopedic prosthetics, with a focus on the economic, technical and systemic shifts that are redefining production paradigms and healthcare business models. It uses an analytical framework that integrates market analysis, technology assessment and process modelling. The study posits that AM is a disruptive general-purpose technology that enables genuinely patient-specific design, fabrication and delivery. Chapter one outlines the standard process chain for 3D printing: digital acquisition, design and lattice generation, slicing, building, post-processing and inspection. It also surveys the main AM techniques and relevant metallic and polymeric biomaterials for implant applications. Chapters two and three investigate the effects of AM on manufacturing processes, business models, and cost structures. The analysis quantifies sensitivities to key process parameters, linking these to mechanical performance, throughput, yield, and total cost of ownership. The discussion also considers the implications for decentralized production, inventory compression, and mass customization, paying particular attention to make-to-order workflows and digital inventories. Chapter four assesses the global diffusion and technological maturity of AM by providing comparative industry and regional benchmarks, mapping technology and manufacturing readiness levels, and documenting changes in the orthopedics, defense, and aerospace sectors. Chapter five addresses the application of additive manufacturing to the production of prosthetic implants, analyzing the enabling technologies and their influence on established manufacturing practices. It provides a global overview of the orthopedic market, including an outlook on the Italian orthopedic sector. The chapter attempts to explain how AM is reshaping the orthopedic business model and identifies barriers and challenges to its broader adoption, including its integration with healthcare systems. The final chapter concludes with a qualitative appraisal of AM's impact on Italy's orthopedic manufacturing sector, supported by dedicated sector data. It concludes with a qualitative appraisal of AM’s impact on Italy’s orthopedic manufacturing sector, supported by dedicated sector data. It highlights how this technology is surpassing the boundaries of conventional surgery by producing unique, fully customized components at a reasonable cost, thereby establishing itself at the heart of the industry's growth.