Orthopedic Surgery Planning Based on the Integration of Reverse Engineering and Rapid Prototyping

This paper describes orthopedic surgical planning based on the integration of RE and RP. Using symmetrical characteristics of the human body, CAD data of the original bone without damages for the injured extent are generated from a mirror transformation of undamaged bone data for the uninjured extent. The physical model before the injury is manufactured from RP apparatus. Surgical planning, such as the selection of the proper implant, pre-forming of the implant, decision of fixation positions and incision sizes, etc., is determined by a physical simulation using the physical model. In order to examine the applicability and efficiency of surgical planning technology for orthopedics, various case studies, such as a proximal tibia plateau fracture, a distal tibia comminuted fracture and an iliac wing fracture of pelvis, are carried out. As a result of the examination, it has been shown that the orthopedic surgical planning based on the integration of RE and RP is an efficient surgical tool.Mechanical Engineerin

Expanding Rapid Prototyping for Electronic Systems Integration of Arbitrary Form

An innovative method for rapid prototyping (RP) of electronic circuits with components characteristic of typical electronics applications was demonstrated using an enhanced version of a previously developed hybrid stereolithography (SL) and direct write (DW) system, where an existing SL machine was integrated with a three-axis DW fluid dispensing system for combined arbitrary form electronic systems manufacturing. This paper presents initial efforts at embedding functional electronic circuits using the hybrid SL/DW system. A simple temperature-sensitive circuit was selected, which oscillated an LED at a frequency proportional to the temperature sensed by the thermistor. The circuit was designed to incorporate all the required electronic components within a 2.5” x 2” x 0.5” SL part. Electrical interconnects between electronic components were deposited on the SL part with a DW system using silver conductive ink lines. Several inks were deposited, cured, and tested on a variety of SL resin substrates, and the E 1660 ink (Ercon Inc, Wareham, MA) was selected due to its measured lowest average resistivity on the SL substrates. The finished circuit was compared with Printed Circuit Board (PCB) technology for functionality. The electronic components used here include a low voltage battery, LM 555 timer chip, resistors, a thermistor, capacitors, and Light Emitting Diodes (LEDs). This circuit was selected because it (1) represented a simple circuit combining many typically used electronic components and thus provided a useful demonstration for integrated electronic systems manufacturing applicable to a wide variety of devices, and (2) provided an indication of the parasitic resistances and capacitances introduced by the fabrication process due to its sensitivity to manufacturing variation. The hybrid technology can help achieve significant size reductions, enable systems integration in atypical forms, a natural resistance to reverse engineering and possibly increase maximum operating temperatures of electronic circuits as compared to the traditional PCB process. This research demonstrates the ability of the hybrid SL/DW technology for fabricating combined electronic systems for unique electronics applications in which arbitrary form is a requirement and traditional PCB technology cannot be used.Mechanical Engineerin

3D-printing techniques in a medical setting : a systematic literature review

Background: Three-dimensional (3D) printing has numerous applications and has gained much interest in the medical world. The constantly improving quality of 3D-printing applications has contributed to their increased use on patients. This paper summarizes the literature on surgical 3D-printing applications used on patients, with a focus on reported clinical and economic outcomes. Methods: Three major literature databases were screened for case series (more than three cases described in the same study) and trials of surgical applications of 3D printing in humans. Results: 227 surgical papers were analyzed and summarized using an evidence table. The papers described the use of 3D printing for surgical guides, anatomical models, and custom implants. 3D printing is used in multiple surgical domains, such as orthopedics, maxillofacial surgery, cranial surgery, and spinal surgery. In general, the advantages of 3D-printed parts are said to include reduced surgical time, improved medical outcome, and decreased radiation exposure. The costs of printing and additional scans generally increase the overall cost of the procedure. Conclusion: 3D printing is well integrated in surgical practice and research. Applications vary from anatomical models mainly intended for surgical planning to surgical guides and implants. Our research suggests that there are several advantages to 3D- printed applications, but that further research is needed to determine whether the increased intervention costs can be balanced with the observable advantages of this new technology. There is a need for a formal cost-effectiveness analysis

Digital design of medical replicas via desktop systems: shape evaluation of colon parts

In this paper, we aim at providing results concerning the application of desktop systems for rapid prototyping of medical replicas that involve complex shapes, as, for example, folds of a colon. Medical replicas may assist preoperative planning or tutoring in surgery to better understand the interaction among pathology and organs. Major goals of the paper concern with guiding the digital design workflow of the replicas and understanding their final performance, according to the requirements asked by the medics (shape accuracy, capability of seeing both inner and outer details, and support and possible interfacing with other organs). In particular, after the analysis of these requirements, we apply digital design for colon replicas, adopting two desktop systems. ,e experimental results confirm that the proposed preprocessing strategy is able to conduct to the manufacturing of colon replicas divided in self-supporting segments, minimizing the supports during printing. ,is allows also to reach an acceptable level of final quality, according to the request of having a 3D presurgery overview of the problems. ,ese replicas are compared through reverse engineering acquisitions made by a structured-light system, to assess the achieved shape and dimensional accuracy. Final results demonstrate that low-cost desktop systems, coupled with proper strategy of preprocessing, may have shape deviation in the range of ±1 mm, good for physical manipulations during medical diagnosis and explanation

A novel updating modelling methodology for free-form surface modifications in the early stages of design

The paper describes the first implementation of a method in which an initial CAD model is updated from a physical model. The method is based on image-mapping in which an initial CAD model is updated from images of a soft rapid prototype model (RPM) which has been sculpted in order to carry out formal developments. The RP model is made by a 3Dimensional-colour printer, has a built-in contrasting grid composed by parallel planes in the X, Y and/or Z co-ordinates and has special consistency allowing it to be easily sculpted with hand modifications. During the sculpting process changes on the surface affect the lines on the RPM, which are the external presence of the internal grid planes and are corresponding to the initial CAD construction lines. These lines (profiles) then are visually contrasted by making use of identical perspective transformations and viewpoints for the virtual model and the RP model image. The initial CAD model is then updated by modifying the surface’s construction lines to match the lines on the RP image by moving control points, such as in the Z direction

An approach for real world data modelling with the 3D terrestrial laser scanner for built environment

Capturing and modelling 3D information of the built environment is a big challenge. A number of techniques and technologies are now in use. These include EDM, GPS, and photogrammetric application, remote sensing and traditional building surveying applications. However, use of these technologies cannot be practical and efficient in regard to time, cost and accuracy. Furthermore, a multi disciplinary knowledge base, created from the studies and research about the regeneration aspects is fundamental: historical, architectural, archeologically, environmental, social, economic, etc. In order to have an adequate diagnosis of regeneration, it is necessary to describe buildings and surroundings by means of documentation and plans. However, at this point in time the foregoing is considerably far removed from the real situation, since more often than not it is extremely difficult to obtain full documentation and cartography, of an acceptable quality, since the material, constructive pathologies and systems are often insufficient or deficient (flat that simply reflects levels, isolated photographs,..). Sometimes the information in reality exists, but this fact is not known, or it is not easily accessible, leading to the unnecessary duplication of efforts and resources. In this paper, we discussed 3D laser scanning technology, which can acquire high density point data in an accurate, fast way. Besides, the scanner can digitize all the 3D information concerned with a real world object such as buildings, trees and terrain down to millimetre detail Therefore, it can provide benefits for refurbishment process in regeneration in the Built Environment and it can be the potential solution to overcome the challenges above. The paper introduce an approach for scanning buildings, processing the point cloud raw data, and a modelling approach for CAD extraction and building objects classification by a pattern matching approach in IFC (Industry Foundation Classes) format. The approach presented in this paper from an undertaken research can lead to parametric design and Building Information Modelling (BIM) for existing structures. Two case studies are introduced to demonstrate the use of laser scanner technology in the Built Environment. These case studies are the Jactin House Building in East Manchester and the Peel building in the campus of University Salford. Through these case studies, while use of laser scanners are explained, the integration of it with various technologies and systems are also explored for professionals in Built Environmen

Survey on Additive Manufacturing, Cloud 3D Printing and Services

Cloud Manufacturing (CM) is the concept of using manufacturing resources in a service oriented way over the Internet. Recent developments in Additive Manufacturing (AM) are making it possible to utilise resources ad-hoc as replacement for traditional manufacturing resources in case of spontaneous problems in the established manufacturing processes. In order to be of use in these scenarios the AM resources must adhere to a strict principle of transparency and service composition in adherence to the Cloud Computing (CC) paradigm. With this review we provide an overview over CM, AM and relevant domains as well as present the historical development of scientific research in these fields, starting from 2002. Part of this work is also a meta-review on the domain to further detail its development and structure

The potential of additive manufacturing in the smart factory industrial 4.0: A review

Additive manufacturing (AM) or three-dimensional (3D) printing has introduced a novel production method in design, manufacturing, and distribution to end-users. This technology has provided great freedom in design for creating complex components, highly customizable products, and efficient waste minimization. The last industrial revolution, namely industry 4.0, employs the integration of smart manufacturing systems and developed information technologies. Accordingly, AM plays a principal role in industry 4.0 thanks to numerous benefits, such as time and material saving, rapid prototyping, high efficiency, and decentralized production methods. This review paper is to organize a comprehensive study on AM technology and present the latest achievements and industrial applications. Besides that, this paper investigates the sustainability dimensions of the AM process and the added values in economic, social, and environment sections. Finally, the paper concludes by pointing out the future trend of AM in technology, applications, and materials aspects that have the potential to come up with new ideas for the future of AM explorations

A novel design process of low cost 3D printed ambidextrous finger designed for an ambidextrous robotic hand

This paper presents the novel mechanical design of an ambidextrous finger specifically designed for an ambidextrous anthropomorphic robotic hand actuated by pneumatic artificial muscles. The ambidextrous nature of design allows fingers to perform both left and right hand movements. The aim of our design is to reduce the number of actuators, increase the range of movements with best possible range ideally greater than a common human finger. Four prototypes are discussed in this paper; first prototype is focused on the choice of material and to consider the possible ways to reduce friction. Second prototype is designed to investigate the tendons routing configurations. Aim of third and fourth prototype is to improve the overall performance and to maximize the grasping force. Finally, a unified design (Final design) is presented in great detail. Comparison of all prototypes is done from different angles to evaluate the best design. The kinematic features of intermediate mode have been analysed to optimize both the flexibility and the robustness of the system, as well as to minimize the number of pneumatic muscles. The final design of an ambidextrous finger has developed, tested and 3D printed