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Article
Publication date: 12 June 2023

Matthew Philip Masterton, David Malcolm Downing, Bill Lozanovski, Rance Brennan B. Tino, Milan Brandt, Kate Fox and Martin Leary

This paper aims to present a methodology for the detection and categorisation of metal powder particles that are partially attached to additively manufactured lattice structures…

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Abstract

Purpose

This paper aims to present a methodology for the detection and categorisation of metal powder particles that are partially attached to additively manufactured lattice structures. It proposes a software algorithm to process micro computed tomography (µCT) image data, thereby providing a systematic and formal basis for the design and certification of powder bed fusion lattice structures, as is required for the certification of medical implants.

Design/methodology/approach

This paper details the design and development of a software algorithm for the analysis of µCT image data. The algorithm was designed to allow statistical probability of results based on key independent variables. Three data sets with a single unique parameter were input through the algorithm to allow for characterisation and analysis of like data sets.

Findings

This paper demonstrates the application of the proposed algorithm with three data sets, presenting a detailed visual rendering derived from the input image data, with the partially attached particles highlighted. Histograms for various geometric attributes are output, and a continuous trend between the three different data sets is highlighted based on the single unique parameter.

Originality/value

This paper presents a novel methodology for non-destructive algorithmic detection and categorisation of partially attached metal powder particles, of which no formal methods exist. This material is available to download as a part of a provided GitHub repository.

Details

Rapid Prototyping Journal, vol. 29 no. 7
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 30 August 2022

Rupinder Singh, Anish Das and Arun Anand

This study aims to design and fabricate a customized multi-rooted dental implant (MRDI) for a canine strategic tooth to reduce surgical time/effort, and better assembly features…

Abstract

Purpose

This study aims to design and fabricate a customized multi-rooted dental implant (MRDI) for a canine strategic tooth to reduce surgical time/effort, and better assembly features, leading to enhanced primary and secondary stability and load-bearing capabilities by direct-metal laser sintering (DMLS).

Design/methodology/approach

A fractured tooth of a male German Shepherd three-year-old dog (extracted from a cadaver) was selected as the subject for the proposed work. The computer-aided design model of the implant was developed on SOLIDWORKS after a detailed review of literature and consultation with a veterinary doctor about the surgical procedures. Static stress analysis on the implant assembly and residual stress analysis with boundary distortion were performed on each part of the implant subassembly to ensure the fool-proof design.

Findings

The functional prototype of the innovative MRDI assembly through DMLS was successfully prepared with acceptable dimensional stability, surface roughness (Ra) and refined microstructure. The 3D printed functional prototype was observed to be residual stress-proof during printing and can bear up to 800 N bite force (required for an adult dog).

Originality/value

Innovative MRDI assembly has been 3D printed by using 17–4 precipitate hardened stainless steel without compromising the strength and can be implanted without bone grafting for better primary stability. Also, the prepared implant will be better for secondary stability due to enhanced osseointegration.

Details

Rapid Prototyping Journal, vol. 29 no. 3
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 25 May 2023

Ashwani Kumar and Deepak Chhabra

This study aims to explore the potential benefits favoring the adaptation of structural optimization techniques in the additive manufacturing (AM) of medical utilities to meet the…

Abstract

Purpose

This study aims to explore the potential benefits favoring the adaptation of structural optimization techniques in the additive manufacturing (AM) of medical utilities to meet the repetitive demand for functionally precise customized orthoses. Irregularities encountered during the conventional treatment of tendon injuries can be eschewed using advanced structural simulation in design and innovative splint fabrication using 3D printing.

Design/methodology/approach

A customized mallet finger splint designed from 3D scans was subjected to ANSYS topological simulation comprising multi-level weight reduction to retain optimal mass (100%, 90%, 80%, 70% and 60%). A batch of the four typical 3D printing materials was chosen to conduct a comparative mechanical and thermal stress analysis, facilitating the selection of the optimal one for fabricating functionally adaptive splints. Assurance of structural safety was accomplished through the experimental validation of simulation results against the testing data set of ASTM D695 and ASTM D638 Type-1 specimens over a universal testing machine (UTM). Fused deposition modeling (FDM) 3D printing processed the optimized splint fabrication to assist evaluation of weight reduction percentage, fitting aesthetics, appearance, comfort, practicality and ventilation ease at the user end.

Findings

AM efficacy can efficiently execute the design complexity involved in the topology optimization (TO) results and introduces rehabilitation practicality into the application. Topologically optimized splint provided with favorable comfort, stiffness and strengthening features, offers ventilation ease and structural stability for customized appliances, with 30.52% lighter weight and 121.37% faster heat dissipation than unoptimized one.

Originality/value

The state of art multidisciplinary optimization featured with structural and material optimization attributes can deliberately meet medical necessity for performance-oriented orthotic devices.

Details

Rapid Prototyping Journal, vol. 29 no. 8
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 24 January 2024

Nirmal Singh, Harmanjit Singh Banga, Jaswinder Singh and Rajnish Sharma

This paper aims to prompt ideas amongst readers (especially librarians) about how they can become active partners in knowledge dissemination amongst concerned user groups by…

Abstract

Purpose

This paper aims to prompt ideas amongst readers (especially librarians) about how they can become active partners in knowledge dissemination amongst concerned user groups by implementing 3D printing technology under the “Makerspace.”

Design/methodology/approach

The paper provides a brief account of various tools and techniques used by veterinary and animal sciences institutions for information dissemination amongst the stakeholders and associated challenges with a focus on the use of 3D printing technology to overcome the bottlenecks. An overview of the 3D printing technology has been provided following the instances of use of this novel technology in veterinary and animal sciences. An initiative of the University Library, Guru Angad Dev Veterinary and Animal Sciences University, Ludhiana, to harness the potential of this technology in disseminating information amongst livestock stakeholders has been discussed.

Findings

3D printing has the potential to enhance learning in veterinary and animal sciences by providing hands-on exposure to various anatomical structures, such as bones, organs and blood vessels, without the need for a cadaver. This approach enhances students’ spatial understanding and helps them better understand anatomical concepts. Libraries can enhance their visibility and can contribute actively to knowledge dissemination beyond traditional library services.

Originality/value

The ideas about how to harness the potential of 3D printing in knowledge dissemination amongst livestock sector stakeholders have been elaborated. This promotes creativity amongst librarians enabling them to think how they can engage in knowledge dissemination thinking out of the box.

Details

Library Hi Tech News, vol. 41 no. 2
Type: Research Article
ISSN: 0741-9058

Keywords

Article
Publication date: 10 January 2023

Shrutika Sharma, Vishal Gupta and Deepa Mudgal

The implications of metallic biomaterials involve stress shielding, bone osteoporosis, release of toxic ions, poor wear and corrosion resistance and patient discomfort due to the…

Abstract

Purpose

The implications of metallic biomaterials involve stress shielding, bone osteoporosis, release of toxic ions, poor wear and corrosion resistance and patient discomfort due to the need of second operation. This study aims to use additive manufacturing (AM) process for fabrication of biodegradable orthopedic small locking bone plates to overcome complications related to metallic biomaterials.

Design/methodology/approach

Fused deposition modeling technique has been used for fabrication of bone plates. The effect of varying printing parameters such as infill density, layer height, wall thickness and print speed has been studied on tensile and flexural properties of bone plates using response surface methodology-based design of experiments.

Findings

The maximum tensile and flexural strengths are mainly dependent on printing parameters used during the fabrication of bone plates. Tensile and flexural strengths increase with increase in infill density and wall thickness and decrease with increase in layer height and wall thickness.

Research limitations/implications

The present work is focused on bone plates. In addition, different AM techniques can be used for fabrication of other biomedical implants.

Originality/value

Studies on application of AM techniques on distal ulna small locking bone plates have been hardly reported. This work involves optimization of printing parameters for development of distal ulna-based bone plate with high mechanical strength. Characterization of microscopic fractures has also been performed for understanding the fracture behavior of bone plates.

Details

Rapid Prototyping Journal, vol. 29 no. 5
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 18 April 2023

Heena Noh, Kijung Park and Hyun Woo Jeon

As newer high performance polymers in mechanical properties become available for material extrusion-based additive manufacturing, determining infill parameter settings becomes…

Abstract

Purpose

As newer high performance polymers in mechanical properties become available for material extrusion-based additive manufacturing, determining infill parameter settings becomes more important to achieve both operational and mechanical performance of printed outputs. For the material extrusion of carbon fiber reinforced poly-ether-ether-ketone (CFR-PEEK), this study aims not only to identify the effects of infill parameters on both operational and mechanical performance but also to derive appropriate infill settings through a multicriteria decision-making process considering the conflicting effects.

Design/methodology/approach

A full-factorial experimental design to investigate the effects of two major infill parameters (i.e. infill pattern and density) on each performance measure (i.e. printing time, sample mass, energy consumption and maximum tensile load) is separately performed to derive the best infill settings for each measure. Focusing on energy consumption for operational performance and maximum tensile load for mechanical performance, the technique for order preference by similarity to ideal solution is further used to identify the most appropriate infill settings given relative preferences on the conflicting performance measures.

Findings

The results show that the honeycomb pattern type with 25% density is consistently identified as the best for the operational performance measures, while the triangular pattern with 100% density is the best for the mechanical performance measure. Moreover, it is suggested that certain ranges of preference weights on operational and mechanical performance can guide the best parameter settings for the overall material extrusion performance of CFR-PEEK.

Originality/value

The findings from this study can help practitioners selectively decide on infill parameters by considering both operational and mechanical aspects and their possible trade-offs.

Details

Rapid Prototyping Journal, vol. 29 no. 7
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 19 January 2024

Natthawut Daoset, Samroeng Inglam, Sujin Wanchat and Nattapon Chantarapanich

This paper aims to investigate the influence of post-curing temperature, post-curing time and gamma ray irradiation dose upon the tensile and compressive mechanical properties of…

Abstract

Purpose

This paper aims to investigate the influence of post-curing temperature, post-curing time and gamma ray irradiation dose upon the tensile and compressive mechanical properties of the medical graded vat photopolymerization parts.

Design/methodology/approach

Medical graded vat photopolymerization specimens, made from photopolymer resin, were fabricated using bottom-up vat photopolymerization machine. Tensile and compressive tests were conducted to assess the mechanical properties. The specimens were categorized into uncured and post-curing groups. Temperature post-processing and/or gamma irradiation exposure were for post-curing specimens. The post-curing parameters considered included temperature levels of 50°C, 60°C and 70°C, with 1, 2, 3 and 4 h periods. For the gamma irradiation, the exposure doses were 25, 50, 75 and 100 kGy.

Findings

Post-curing improved the mechanical properties of medical graded vat photopolymerization parts for both tensile and compressive specimens. Post-curing temperature greater than 50°C or a prolonged post-curing period of more than 1 h made insignificant changes or deterioration in mechanical properties. The optimal post-curing condition was therefore a 50°C post-curing temperature with 1 h post-curing time. Exposure to gamma ray improved the compressive mechanical properties, but deteriorated tensile mechanical properties. Higher gamma irradiation doses could decrease the mechanical properties and also make the part more brittle, especially for doses more than 25 kGy.

Originality/value

The obtained results would be beneficial to the medical device manufacturer who fabricated the invasive temporary contact personalized surgical instruments by vat photopolymerization technique. In addition, it also raised awareness in excessive gamma sterilization in the medical graded vat photopolymerization parts.

Details

Rapid Prototyping Journal, vol. 30 no. 3
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 1 January 2024

Shrutika Sharma, Vishal Gupta, Deepa Mudgal and Vishal Srivastava

Three-dimensional (3D) printing is highly dependent on printing process parameters for achieving high mechanical strength. It is a time-consuming and expensive operation to…

Abstract

Purpose

Three-dimensional (3D) printing is highly dependent on printing process parameters for achieving high mechanical strength. It is a time-consuming and expensive operation to experiment with different printing settings. The current study aims to propose a regression-based machine learning model to predict the mechanical behavior of ulna bone plates.

Design/methodology/approach

The bone plates were formed using fused deposition modeling (FDM) technique, with printing attributes being varied. The machine learning models such as linear regression, AdaBoost regression, gradient boosting regression (GBR), random forest, decision trees and k-nearest neighbors were trained for predicting tensile strength and flexural strength. Model performance was assessed using root mean square error (RMSE), coefficient of determination (R2) and mean absolute error (MAE).

Findings

Traditional experimentation with various settings is both time-consuming and expensive, emphasizing the need for alternative approaches. Among the models tested, GBR model demonstrated the best performance in predicting both tensile and flexural strength and achieved the lowest RMSE, highest R2 and lowest MAE, which are 1.4778 ± 0.4336 MPa, 0.9213 ± 0.0589 and 1.2555 ± 0.3799 MPa, respectively, and 3.0337 ± 0.3725 MPa, 0.9269 ± 0.0293 and 2.3815 ± 0.2915 MPa, respectively. The findings open up opportunities for doctors and surgeons to use GBR as a reliable tool for fabricating patient-specific bone plates, without the need for extensive trial experiments.

Research limitations/implications

The current study is limited to the usage of a few models. Other machine learning-based models can be used for prediction-based study.

Originality/value

This study uses machine learning to predict the mechanical properties of FDM-based distal ulna bone plate, replacing traditional design of experiments methods with machine learning to streamline the production of orthopedic implants. It helps medical professionals, such as physicians and surgeons, make informed decisions when fabricating customized bone plates for their patients while reducing the need for time-consuming experimentation, thereby addressing a common limitation of 3D printing medical implants.

Details

Rapid Prototyping Journal, vol. 30 no. 3
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 13 October 2022

Smitkumar Savsani, Shamsher Singh and Harlal Singh Mali

Medical devices are undergoing rapid changes because of the increasing affordability of advanced technologies like additive manufacturing (AM) and three-dimensional scanning. New…

Abstract

Purpose

Medical devices are undergoing rapid changes because of the increasing affordability of advanced technologies like additive manufacturing (AM) and three-dimensional scanning. New avenues are available for providing solutions and comfort that were not previously conceivable. The purpose of this paper is to provide a comprehensive review of the research on developing prostheses using AM to understand the opportunities and challenges in the domain. Various studies on prosthesis development using AM are investigated to explore the scope of integration of AM in prostheses development.

Design/methodology/approach

A review of key publications from the past two decades was conducted. Integration of AM and prostheses development is reviewed from the technologies, materials and functionality point of view to identify challenges, opportunities and future scope.

Findings

AM in prostheses provides superior physical and cognitive ergonomics and reduced cost and delivery time. Patient-specific, lightweight solutions for complex designs improve comfort, functionality and clinical outcomes. Compared to existing procedures and methodologies, using AM technologies in prosthetics could benefit a large population.

Originality/value

This paper helps investigate the impact of AM and related technology in the field of prosthetics and can also be viewed as a collection of relevant medical research and findings.

Details

Rapid Prototyping Journal, vol. 29 no. 4
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 29 November 2023

Rupinder Singh, Gurwinder Singh and Arun Anand

The purpose of this paper is to design and manufacture an intelligent 3D printed sensor to monitor the re-occurrence of diaphragmatic hernia (DH; after surgery) in bovines as an…

Abstract

Purpose

The purpose of this paper is to design and manufacture an intelligent 3D printed sensor to monitor the re-occurrence of diaphragmatic hernia (DH; after surgery) in bovines as an Internet of Things (IOT)-based solution.

Design/methodology/approach

The approach used in this study is based on a bibliographic analysis for the re-occurrence of DH in the bovine after surgery. Using SolidWorks and ANSYS, the computer-aided design model of the implant was 3D printed based on literature and discussions on surgical techniques with a veterinarian. To ensure the error-proof design, load test and strain–stress rate analyses with boundary distortion have been carried out for the implant sub-assembly.

Findings

An innovative IOT-based additive manufacturing solution has been presented for the construction of a mesh-type sensor (for the health monitoring of bovine after surgery).

Originality/value

An innovative mesh-type sensor has been fabricated by integration of metal and polymer 3D printing (comprising 17–4 precipitate hardened stainless steel and polyvinylidene fluoride-hydroxyapatite-chitosan) without sacrificing strength and specific absorption ratio value.

Details

Rapid Prototyping Journal, vol. 30 no. 2
Type: Research Article
ISSN: 1355-2546

Keywords

1 – 10 of 18