A processing algorithm for freeform fabrication of heterogeneous structures

Rapid Prototyping Journal, Vol. 10, No. 5, 2004, pp. 316-326. Retrieved April 2006 from http://www.pages.drexel.edu/~sunwei/WSUN-Papers/RPJ-Heterogeneous-Fabrication.pdfA processing algorithm for freeform fabrication of heterogeneous structures is presented. The algorithm was developed based on the heterogeneous fabrication structural model, which was constructed from the STL based multi-material volume regions and with material identifications. The reasoning Boolean operation based modelling approach was used to construct the heterogeneous CAD assembly and to output the needed STL format. Procedures for generating the database hierarchy and the storage of the heterogeneous structural model, and derivation for developing the processing algorithm for layered fabrication of heterogeneous structure are presented. The developed algorithm was applied to a heterogeneous structure consisting of two discrete material volumes, and the detailed processing path is described

Process planning for the subtractive rapid manufacturing of heterogeneous materials: Applications for automated bone implant manufacturing

This research presents a subtractive rapid manufacturing process for heterogeneous materials, in particular for custom shaped bone implants. Natural bone implants are widely used in the treatment of severe fractures or in tumor removal. In order for the human body to accept the bone implant material and heal properly, it is essential that the bone implant should be both mechanically and biologically compatible. Currently, the challenge of having correctly shaped natural bone implants created from an appropriate material is met through hand-shaping done by a surgeon. CNC-RP is a rapid machining method and software that can realize a fully automated Subtractive Rapid Prototyping (RP) process, using a 3-axis milling machine with a 4th axis indexer for multiple setup orientations. It is capable of creating accurate bone implants from different clinically relevant material including natural bone. However, there are major challenges that need to be overcome in order to implement automated shape machining of natural bones. They are summarized as follows: (1) Unlike homogeneous source materials for which a part can be machined from any arbitrary location within the original stock, for the case of donor bones, the site and orientation of implant harvest need to consider the nature of the heterogeneous internal bony architecture. (2) For the engineered materials, the source machining stock is in the convenient form of geometrically regular shapes such as cylinders or rectangular blocks and the entities of sacrificial supports can connect the part to the remaining stock material. However, irregularly-shaped bones and the heterogeneity of bone make the design of a fixture system for machining much more complicated. In this dissertation, two major areas of research are presented to overcome these challenges and enable automated process planning for a new rapid manufacturing technique for natural bone implants. Firstly, a new method for representing heterogeneous materials using nested STL shells is proposed. The nested shells model is called the Matryoshka mode, based in particular on the density distribution of human bone. The Matryoshka model is generated via an iterative process of thresholding the Hounsfield Unit (HU) data from a computed tomography (CT) scan, thereby delineating regions of progressively increasing bone density. Then a harvesting algorithm is developed to determine a suitable location to generate the bone implant from within the donor bone is presented. In this harvesting algorithm, a density score and similarity score are calculated to evaluate the overall effectiveness of that harvest site. In the second research area, an automated fixturing system is proposed for securing the bone implant during the machining process. The proposed method uses a variant of sacrificial supports (stainless surgical screws) to drill into appropriate locations and orientations through the free-form shaped donor bone, terminating at proper locations inside the solid part model of the implant. This automated fixturing system has been applied to machine several bone implants from surrogate bones to 3D printed Matryoshka models. Finally, the algorithms that are developed for setup planning are implemented in a CAD/CAM software add-on called CNC-RPbio . The results of this research could lead to a clinically relevant rapid machining process for custom shaped bone implants, which could create unique implants at the touch of a button. The implication of such high accuracy implants is that patients could benefit from more accurate reconstructions of trauma sites, with better fixation stability; leading to potentially shorter surgeries, less revisions, shorter recovery times and less likelihood of post-traumatic osteoarthritis, to name a few

Biomimetic design and fabrication of tissue engineered scaffolds using computer aided tissue engineering

The field of tissue engineering brings together the multidisciplinary research of life sciences and engineering to seek man-made substitutes for the regeneration of damaged tissue or organs. A key component in tissue engineering is the use of porous scaffolds to guide cells for attachment, proliferation and differentiation in the tissue regenerative process. Upon satisfactory in-vitro culture, this engineered living scaffold is implanted into the regeneration site of the patient to function as the tissue substitute. Conventional processing techniques for the fabrication of scaffolds often encounter difficulties in the precise control of the internal architecture, interconnectivity and distribution of pores within the scaffold. These challenges, along with the advances in biology, medicine, and information technology for tissue engineering applications, have led to the development of a new field of Computer Aided Tissue Engineering (CATE).CATE enables a systematic application of computer-aided technologies, i.e., computer-aided design (CAD), image processing, computer-aided manufacturing (CAM), and solid freeform fabrication (SFF) for modeling, designing, simulation, and manufacturing of biological tissue and organ substitutes. Through the use of CATE, the design of intricate three dimensional architecture of scaffold can be realized and these scaffolds can be fabricated with reproducible accuracy to assist biologists in studying complex tissue engineering problems. This thesis reports a research addressing some of the challenges in applying the CATE approach for the biomimetic design and freeform fabrication of tissue scaffolds. The major research accomplishments reported in this thesis include: a) The development of a BioCAD modeling technique for the design and representation of patient specific 3D tissue models based on non-invasive medical image data. b) The development of a biomimetic design approach for design of load bearing tissue scaffold subject to multiple biophysical, geometrical and manufacturing requirements. This includes the design of the unit cell micro-architecture based on tissue morphologies, unit cell characterization and evaluation of the mechanical and transport properties, and the use of unit cells as building block to design anatomic tissue scaffold replacements. c) The development of a CAD based path planning procedure through a direct slicing algorithm which can convert a neutral ISO (International Standards Organization) standardized STEP (Standard for the Exchange of Product Data) formatted NURBS (Non-Uniform Rational B-Spline) geometric representation to a tool path instruction set for layered freeform fabrication. d) The development of a novel Internal Architecture Design (IAD) approach for the mapping of characteristic patterns of the unit cell micro-architectures designed within the 3D scaffold. This design approach is implemented into a process algorithm that converts these 2D patterns to tool path datasets for the 3DP™ (threedimensional printing) and extrusion based freeform fabrication.CATE enables many novel approaches in modeling, design, and fabrication of complex tissue substitutes with enhanced functionality for research in patient specific implant analysis and simulation, image guided surgical planning and scaffold guided tissue engineering. The research will also enable cell biologists and engineers to expand their scope of research and study in the field of tissue engineering and regenerative medicine.Ph.D., Mechanical Engineering -- Drexel University, 200