Case Study: NuVasive achieves rapid commercialization of FDA‑cleared 3D‑printed Modulus spinal implants with 3D Systems

NuVasive Taps AM Ecosystem to Optimize Spine Implant Technology

NuVasive, a spinal device company, saw additive manufacturing (AM) as a way to improve clinical outcomes but lacked in‑house AM expertise. The challenge was to adopt novel AM processes, validate a new implant design for surgeons, and navigate regulatory requirements without disrupting existing manufacturing capabilities.

NuVasive partnered with 3D Systems and its Customer Innovation Centers to apply direct metal printing and topological optimization, refining print strategies, metallurgy and qualification data for FDA submission. The collaboration produced the Modulus® family—3D‑printed, porous implants with improved radiolucency and load‑sharing properties—cleared for market in about 14 months, with NuVasive now moving toward in‑house titanium printing and scalable production.

NuVasive

Jeremy Malik

Director