scholarly journals Custom TMJ Hemi-joint Fabrication Process

2008 ◽  
Vol 2 (2) ◽  
Author(s):  
Joel L. Kuhlmann ◽  
Sean McEligot
Keyword(s):  
Temporomandibular Joint ◽  
Mayo Clinic ◽  
Fused Deposition Modeling ◽  
High Strength ◽  
Fabrication Process ◽  
Implant Design ◽  
3D Cad ◽  
Fused Deposition ◽  
Joint Disorder ◽  
Unique Shape

Temporomandibular joint disorder afflicts 10 million Americans, many of whom have osteoarthritis of the temporomandibular joint (TMJ). This condition can inflict severe pain and disrupt the lives of sufferers in many ways. Partial or total replacement of the temporomandibular joint is a last resort treatment option. Surgeons at Mayo Clinic believe a new hemijoint implant design coupled with unique surgical technique can improve joint kinematics and reduce pain. They are currently investigating a patent-pending implant design in a series of patient trials. The Division of Engineering at Mayo Clinic has developed a novel process for fabricating TMJ implants for this study. Computed Tomagraphy (CT) images of the surgical site are first converted into a 3D computer model of the mandibular fossa and condyle area. A fused deposition modeling process is used to create a plastic model of the anatomy, and the surgeons use that model to create a wax mold of the implant. The wax mold is laser scanned to create a 3D CAD model that can be machined with a standard four axis milling machine out of implant grade CoCrMo material. Because of the unique shape of the implant, the machining takes place in two phases, with the implant being refixtured between machining phases using a high strength industrial adhesive. Finally, the implant is polished, inspected, passivated and sterilized for surgery. This fabrication process has allowed Mayo Clinic surgeons to quickly and accurately test their unique implant design.

scholarly journals Are We Able to Print Components as Strong as Injection Molded?—Comparing the Properties of 3D Printed and Injection Molded Components Made from ABS Thermoplastic

2021 ◽  
Vol 11 (15) ◽  
pp. 6946
Author(s):  
Bartłomiej Podsiadły ◽  
Andrzej Skalski ◽  
Wiktor Rozpiórski ◽  
Marcin Słoma
Keyword(s):  
Tensile Strength ◽  
Injection Molding ◽  
Mechanical Strength ◽  
Cross Section ◽  
Fused Deposition Modeling ◽  
High Strength ◽  
Large Cross Section ◽  
Fused Deposition ◽  
Injection Molded ◽  
The Cross

In this paper, we are focusing on comparing results obtained for polymer elements manufactured with injection molding and additive manufacturing techniques. The analysis was performed for fused deposition modeling (FDM) and single screw injection molding with regards to the standards used in thermoplastics processing technology. We argue that the cross-section structure of the sample obtained via FDM is the key factor in the fabrication of high-strength components and that the dimensions of the samples have a strong influence on the mechanical properties. Large cross-section samples, 4 × 10 mm2, with three perimeter layers and 50% infill, have lower mechanical strength than injection molded reference samples—less than 60% of the strength. However, if we reduce the cross-section dimensions down to 2 × 4 mm2, the samples will be more durable, reaching up to 110% of the tensile strength observed for the injection molded samples. In the case of large cross-section samples, strength increases with the number of contour layers, leading to an increase of up to 97% of the tensile strength value for 11 perimeter layer samples. The mechanical strength of the printed components can also be improved by using lower values of the thickness of the deposited layers.

Mechanical performance of honeycomb sandwich structures built by FDM printing technique

2021 ◽  
pp. 089270572199789
Author(s):  
S Gohar ◽  
G Hussain ◽  
A Ali ◽  
H Ahmad
Keyword(s):  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Sandwich Structures ◽  
Weight Ratio ◽  
High Strength ◽  
Core Material ◽  
Interfacial Bond Strength ◽  
Fused Deposition ◽  
Competitive Prices ◽  
Composite Face

Honey Comb Sandwich Structures (HCSS) have numerous applications in aerospace, automobile, and satellite industry because of their properties like high strength to weight ratio, stiffness and impact strength. Fused Deposition Modeling (FDM) is a process which, through its flexibility, simple processing, short manufacturing time, competitive prices and freedom of design, has an ability to enhance the functionality of HCSS. This paper investigates the mechanical behavior (i.e. flexural, edgewise compression and Interfacial bond strength) of FDM-built HCSS. The influence of face/core material was examined by manufacturing four types of specimens namely ABS core with Composite (PLA + 15% carbon fibers) face sheets, ABS core with PLA face sheets, TPU core with composite face sheets and TPU core with PLA face sheets. To measure the effect of face sheets geometry, raster layup was varied at 0°/90° and 45°/−45°. The mechanical characterization revealed that an optimum combination of materials is ABS core with composite face sheets having raster layup of 0°/90°. This study indicates that HCSS with complex lamination schemes and adequate mechanical properties could be manufactured using FDM which may widen the applications of FDM on an industrial scale.

Application of Rapid Prototyping Technology on Development of Medical Equipment

2014 ◽  
Vol 1030-1032 ◽  
pp. 2326-2329
Author(s):  
Shi Jian Yang ◽  
Zhen Jie Du ◽  
Hai Hong Kang
Keyword(s):  
Rapid Prototyping ◽  
Medical Equipment ◽  
Fused Deposition Modeling ◽  
Effective Means ◽  
Cad Model ◽  
3D Cad ◽  
Fused Deposition ◽  
Laminated Object Manufacturing ◽  
Deposition Modeling ◽  
The Cost

The prototype of a production can be manufactured directly from its 3D CAD model data by using rapid prototyping technology, and can be renewed conveniently after modifying the CAD model. In this paper, the basic principle, typical prototyping systems are introduced, and rapid prototyping methods such as selected laser sintering of powder material, fused deposition modeling of threadlike material and laminated object manufacturing are presented. An application of rapid prototyping technology on design and development of first aid kit is described in detail. It is indicated that rapid prototyping technology is an effective means to lower the cost and shorten the period of development of medical equipment.

Development of a flow-based predictive model for the coalescence of fused deposition modeling filaments

2014 ◽  
Author(s):  
◽  
Brian Graybill
Keyword(s):  
Bond Length ◽  
Fused Deposition Modeling ◽  
Predictive Accuracy ◽  
Weight Ratio ◽  
High Strength ◽  
Accurate Prediction ◽  
Bond Lengths ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
End Use

[ACCESS RESTRICTED TO THE UNIVERSITY OF MISSOURI AT AUTHOR'S REQUEST.] As rapid prototyping processes continue to be developed, there is increasing use of such processes for the production of end-use parts. Fused deposition modeling (FDM) is a particularly favorable method for fabricating end-use parts because of the wide selection of materials available for the process such as Ultem 9085, prized by the aerospace industry for its high strength-to-weight ratio. To confidently employ FDM parts in service requires a thorough understanding of their behavior under expected loading conditions and the ability to predict their success for failure in a particular application. The strength of an FDM part is derived from the amount of bonding that occurs between the polymer filaments as they are deposited. Thus, an accurate prediction of this bond length should lead naturally to an accurate prediction of part strength. Models simulating the heat transfer and coalescence experienced by a pair of adjacent filaments are developed and presented. The models are executed across a range of build parameters to help determine flexibility, and provide a value for the predicted bond length. To validate the models, FDM parts are built from Ultem 9085, cross sectioned, and imaged. The images allow measurements of actual bond lengths to be obtained. The measured bond lengths are compared to the predicted bond lengths. Only a select number of bond lengths measurements are obtained because of variations in microstructure corresponding to various build parameters. A predictive accuracy of 95 % is desired, but the model is unable to achieve it due to estimates of critical data that is unavailable and the variability inherent in the FDM process. However, the simulations provide a significant foundation for future modeling efforts aimed at providing a model capable of predicting bond lengths, and therefore strengths, of FDM parts.

A digital design methodology for surgical planning and fabrication of customized mandible implants

2017 ◽  
Vol 23 (1) ◽  
pp. 101-109 ◽  
Author(s):  
Emad Abouel Nasr ◽  
Abdurahman Mushabab Al-Ahmari ◽  
Khaja Moiduddin ◽  
Mohammed Al Kindi ◽  
Ali K. Kamrani
Keyword(s):  
Ct Scan ◽  
Design Methodology ◽  
Fused Deposition Modeling ◽  
Bone Structure ◽  
Biomechanical Study ◽  
Digital Design ◽  
Implant Design ◽  
Element Analysis ◽  
Content Type ◽  
Fused Deposition

Purpose The purpose of this paper is to demonstrate the route to digitize the customized mandible implants consisting of image acquisition, processing, implant design, fitting rehearsal and fabrication using fused deposition modeling and electron beam melting methodologies. Design/methodology/approach Recent advances in the field of rapid prototyping, reverse engineering, medical imaging and image processing have led to new heights in the medical applications of additive manufacturing (AM). AM has gained a lot of attention and interest during recent years because of its high potential in medical fields. Findings Produced mandible implants using casting, milling and machining are of standard sizes and shapes. As each person’s physique and anatomical bone structure are unique, these commercially produced standard implants are manually bent before surgery using trial and error methodology to custom fit the patient’s jaw. Any mismatch between the actual bone and the implant results in implant failure and psychological stress and pain to the patient. Originality/value The novelty in this paper is the construction of the customized mandibular implant from the computed tomography (CT) scan which includes surface reconstruction, implant design with validation and simulation of the mechanical behavior of the design implant using finite element analysis (FEA). There has been few research studies on the design and customization of the implants before surgery, but there had been hardly any study related to customized design implant and evaluating the biomechanical response on the newly designed implant using FEA. Though few studies are related to FEA on the reconstruction plates, but their paper lacks the implant design model and the reconstruction model. In this research study, an integrated framework is developed for the implant design, right from the CT scan of the patient including the softwares involved through out in the study and then performing the biomechanical study on the customized design implant to prove that the designed implant can withstand the biting and loading conditions. The proposed research methodology which includes the interactions between medical practitioners and the implant design engineers can be incorporated to any other reconstruction bone surgeries.

Enhancing the mechanical properties of SCF/PEEK composites in FDM via process-parameter optimization

2021 ◽  
pp. 095400832110036
Author(s):  
Bin Hu ◽  
Zehua Xing ◽  
Weidong Wu ◽  
Xiaojun Zhang ◽  
Huamin Zhou ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Weight Ratio ◽  
High Strength ◽  
Processing Parameters ◽  
High Viscosity ◽  
Polymer Composite Material ◽  
Fused Deposition ◽  
Deposition Modeling

Short-carbon-fiber (SCF)–reinforced poly-ether-ether-ketone (PEEK) is a promising polymer composite material with good biocompatibility, a high strength-to-weight ratio, and low friction properties. In artificial-bone fabrication and other applications with more flexible fabrication demands, fused-deposition modeling (FDM) technology enables the rapid and low-cost fabrication of SCF/PEEK parts with sophisticated structures. Owing to the high viscosity of melting PEEK composites, great challenges, associated with the poor internal interface, need to be overcome before enhanced mechanical properties can be obtained. In this study, key processing parameters and various SCF amounts were studied to investigate their effects on the mechanical properties of PEEK composites. It was revealed that the existence of voids and gaps between the SCF and PEEK led to a decrease in the strength of the composite systems. The FDM processing parameters were tuned to eliminate these defects in the PEEK composites. The tensile strength of the 2% SCF/PEEK sample reached 96.4 MPa, which is comparable to that of PEEK parts prepared by injection molding. Meanwhile, its elastic modulus reached 2.6 GPa, which is 169% higher than that of the bare PEEK sample.

Effect of raster inclinations and part positions on mechanical properties, surface roughness and manufacturing price of printed parts produced by fused deposition method

2020 ◽  
Vol 14 (4) ◽  
pp. 7416-7423
Author(s):  
Mohammed Yunus ◽  
Mohammad S. Alsoufi
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
3D Cad ◽  
Fused Deposition ◽  
Cad Models ◽  
Proper Values

Additive manufacturing (AM) technology has the ability to produce parts or products using data from 3D CAD models based on adding material. Fused deposition modeling (FDM) is among the most popular AM technologies wherein the plastic materials like acrylonitrile-butadiene-styrene filaments get added in the form of semi-molten plastic layers from bottom to top to produce the final product. Besides, the merits of using the FDM process, it faces challenges related to strength, dimensional accuracy, surface finish, and so on. The mechanical, tribological, and surface finish of functional parts is an essential consideration in FDM. In this work, the role of process parameters such as the part positions and raster inclinations involved in the manufacturing of parts by FDM has been evaluated experimentally to obtain the desired properties for reducing production time, the quantity of supporting material, and overall cost including maintenance costs. The study revealed that part position is a more significant parameter than the raster inclinations on the surface roughness and mechanical properties of the FDM parts. It also concludes with the proper values of part positions and raster inclinations for achieving optimal mechanical properties, roughness, and manufacturing costs to withstand operating loading conditions.

scholarly journals Optimization of the fused deposition modeling-based fabrication process for polylactic acid microneedles

2021 ◽  
Vol 7 (1) ◽  
Author(s):  
Libo Wu ◽  
Jongho Park ◽  
Yuto Kamaki ◽  
Beomjoon Kim
Keyword(s):  
Additive Manufacturing ◽  
Polylactic Acid ◽  
Chemical Etching ◽  
Fused Deposition Modeling ◽  
Sensory Nerve ◽  
Nerve Fibers ◽  
Fabrication Process ◽  
Medical Applications ◽  
Fused Deposition ◽  
Deposition Modeling

AbstractA microneedle (MN) array is a novel biomedical device adopted in medical applications to pierce through the stratum corneum while targeting the viable epidermis and dermis layers of the skin. Owing to their micron-scale dimensions, MNs can minimize stimulations of the sensory nerve fibers in the dermis layer. For medical applications, such as wound healing, biosensing, and drug delivery, the structure of MNs significantly influences their mechanical properties. Among the various microfabrication methods for MNs, fused deposition modeling (FDM), a commercial 3D printing method, shows potential in terms of the biocompatibility of the printed material (polylactic acid (PLA)) and preprogrammable arbitrary shapes. Owing to the current limitations of FDM printer resolution, conventional micron-scale MN structures cannot be fabricated without a post-fabrication process. Hydrolysis in an alkaline solution is a feasible approach for reducing the size of PLA needles printed via FDM. Moreover, weak bonding between PLA layers during additive manufacturing triggers the detachment of PLA needles before etching to the expected sizes. Furthermore, various parameters for the fabrication of PLA MNs with FDM have yet to be sufficiently optimized. In this study, the thermal parameters of the FDM printing process, including the nozzle and printing stage temperatures, were investigated to bolster the interfacial bonding between PLA layers. Reinforced bonding was demonstrated to address the detachment challenges faced by PLA MNs during the chemical etching process. Furthermore, chemical etching parameters, including the etchant concentration, environmental temperature, and stirring speed of the etchant, were studied to determine the optimal etching ratio. To develop a universal methodology for the batch fabrication of biodegradable MNs, this study is expected to optimize the conditions of the FDM-based fabrication process. Additive manufacturing was employed to produce MNs with preprogrammed structures. Inclined MNs were successfully fabricated by FDM printing with chemical etching. This geometrical structure can be adopted to enhance adhesion to the skin layer. Our study provides a useful method for fabricating MN structures for various biomedical applications.

Additive manufacturing of fused deposition modeling for carbon fiber-PLA (CF-PLA) composites: The effects of tensile and flexural properties of process parameters

2021 ◽  
Author(s):  
Abhay Mishra ◽  
Vivek Srivastava ◽  
Nitin Gupta
Keyword(s):  
Carbon Fiber ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Processing Parameters ◽  
Variance Analysis ◽  
Flexural Properties ◽  
3D Cad ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Factor Design

Abstract In this paper the effect of process parameters on the tensile and flexural properties has been analyzed. We have used commercially available FDM 3D printer and material (Carbon fiber -PLA). When various processing parameters, especially when no linear processing parameters are defined, the complete factor design of experiments (DOE) is hard to research. Furthermore, a large number of samples are needed to completely exploit the exact processing parameters. The key effects of four processing parameters for the FDM process, i.e. layer height, infill density, printing speed and infill pattern, are examined in this document in the DOE of Taguchi. The mechanical characteristics of the fabricated FDM components express the power of the processing parameters. We have used the Taguchi L9 range of 9 runs with three specimens each to present the work, so 54 different processes were used to make a total of 54 specimens. In comparison to the 3D CAD model, the measurements of the manufactured specimens were tested according to standard ASTM D638 and ASTM D790. Variance analysis (ANOVA) is generated using Design Expert tools in order to assess the importance of variables and their tensile and flexural strength interactions. After doing Variance analysis (ANOVA) we got the exact parameters in which the mechanical properties are higher.

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