Modeling and Simulation in Engineering

This book provides an open platform to establish and share knowledge developed by scholars, scientists, and engineers from all over the world, about various applications of the modeling and simulation in the design process of products, in various engineering fields. The book consists of 12 chapters arranged in two sections (3D Modeling and Virtual Prototyping), reflecting the multidimensionality of applications related to modeling and simulation. Some of the most recent modeling and simulation techniques, as well as some of the most accurate and sophisticated software in treating complex systems, are applied. All the original contributions in this book are jointed by the basic principle of a successful modeling and simulation process: as complex as necessary, and as simple as possible. The idea is to manipulate the simplifying assumptions in a way that reduces the complexity of the model (in order to make a real-time simulation), but without altering the precision of the results

Integration of rapid prototyping and reverse engineering for complex 3D shape design

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1996.Includes bibliographical references (p. 103-105).by David W. Robinson.M.S

Exploring Attacks and Defenses in Additive Manufacturing Processes: Implications in Cyber-Physical Security

Many industries are rapidly adopting additive manufacturing (AM) because of the added versatility this technology offers over traditional manufacturing techniques. But with AM, there comes a unique set of security challenges that must be addressed. In particular, the issue of part verification is critically important given the growing reliance of safety-critical systems on 3D printed parts. In this thesis, the current state of part verification technologies will be examined in the con- text of AM-specific geometric-modification attacks, and an automated tool for 3D printed part verification will be presented. This work will cover: 1) the impacts of malicious attacks on AM using geometrically-modified 3D models, 2) a 3D part reconstruction approach from medical imaging scans, 3) a mesh alignment technique based on point set registration, de- signed to handle abnormal part geometries, and 4) an automatic error detection and defect visualization tool for comparing the geometric similarity of 3D printed parts to their intended geometries

Cost-effective 3D scanning and printing technologies for outer ear reconstruction: Current status

Current 3D scanning and printing technologies offer not only state-of-the-art developments in the field of medical imaging and bio-engineering, but also cost and time effective solutions for surgical reconstruction procedures. Besides tissue engineering, where living cells are used, bio-compatible polymers or synthetic resin can be applied. The combination of 3D handheld scanning devices or volumetric imaging, (open-source) image processing packages, and 3D printers form a complete workflow chain that is capable of effective rapid prototyping of outer ear replicas. This paper reviews current possibilities and latest use cases for 3D-scanning, data processing and printing of outer ear replicas with a focus on low-cost solutions for rehabilitation engineering

THE DEVELOPMENT OF COMPUTATIONAL MODEL THROUGH

Reverse engineering is a process of capturing the geometry by existing physical objects and used the data obtained as a foundation for re-designing or designing something new. Laser scanners are commonly used since they can be a sample of threedimensional range images fast and very accurately relative to other technologies.The complexity of the process to re-modelling the objects is very obvious since there-shaping of the object is more to surface consideration and not solid modelling.This paper employs and compares two methods of reverse engineering. First, conventional method is used where the parts of a car side mirror are drawn from direct measurement. Second, the detail drawings of the same parts are generated through three-dimensional scanning software. For the conventional method, direct measurements are obtained using a vernier calliper, ruler and micrometer. For the later approach, three-dimensional scanning software is used, where the side mirror and its components are scanned to obtain the initial feature, which later on is refined to achieve an accurate computational model. Based on the final computational model, both methods are compared and analysed. This paper is aimed to exhibit a computer aided reverse engineering approach in modelling a product through both methods. Acomprehensive methodology is presented through a case study approach

Construction of Physics-based brain atlas and its application

Ph.DDOCTOR OF PHILOSOPH

Unveiling the prospects of point-of-care 3D printing of Polyetheretherketone (PEEK) patient-specific implants

Additive manufacturing (AM) or three-dimensional (3D) printing is rapidly gaining acceptance in the healthcare sector. With the availability of low-cost desktop 3D printers and inexpensive materials, in-hospital or point-of-care (POC) manufacturing has gained considerable attention in personalized medicine. Material extrusion-based [Fused Filament Fabrication (FFF)] 3D printing of low-temperature thermoplastic polymer is the most commonly used 3D printing technology in hospitals due to its ease of operability and availability of low-cost machines. However, this technology has been limited to the production of anatomical biomodels, surgical guides, and prosthetic aids and has not yet been adopted into the mainstream production of patient-specific or customized implants. Polyetheretherketone (PEEK), a high-performance thermoplastic polymer, has been used mainly in reconstructive surgeries as a reliable alternative to other alloplastic materials to fabricate customized implants. With advancements in AM systems, prospects for customized 3D printed surgical implants have emerged, increasing attention for POC manufacturing. A customized implant may be manufactured within few hours using 3D printing, allowing hospitals to become manufacturers. However, manufacturing customized implants in a hospital environment is challenging due to the number of actions necessary to design and fabricate the implants. The focus of this thesis relies on material extrusion-based 3D printing of PEEK patient-specific implants (PSIs). The ambitious challenge was to bridge the performance gap between 3D printing of PEEK PSIs for reconstructive surgery and the clinical applicability at the POC by taking advantage of recent developments in AM systems. The main reached milestones of this project include: (i) assessment of the fabrication feasibility of PEEK surgical implants using material extrusion-based 3D printing technology, (ii) incorporation of a digital clinical workflow for POC manufacturing, (iii) assessment of the clinical applicability of the POC manufactured patient-specific PEEK scaphoid prosthesis, (iv) visualization and quantification of the clinical reliability of the POC manufactured patient-specific PEEK cranial implants, and (v) assessment of the clinical performance of the POC manufactured porous patient-specific PEEK orbital implants. During this research work, under the first study, we could demonstrate the prospects of FFF 3D printing technology for POC PEEK implant manufacturing. It was established that FFF 3D printing of PEEK allows the construction of complex anatomical geometries which cannot be manufactured using other technologies. With a clinical digital workflow implementation at the POC, we could further illustrate a smoother integration and faster implant production (within two hours) potential for a complex-shaped, patented PEEK patient-specific scaphoid prosthesis. Our results revealed some key challenges during the FFF printing process, exploring the applicability of POC manufactured FFF 3D printed PEEK customized implants in craniofacial reconstructions. It was demonstrated that optimal heat distribution around the cranial implants and heat management during the printing process are essential parameters that affect crystallinity, and thus the quality of the FFF 3D printed PEEK cranial implants. At this stage of the investigation, it was observed that the root mean square (RMS) values for dimensional accuracy revealed higher deviations in large-sized cranial prostheses with “horizontal lines” characteristics. Further optimization of the 3D printer, a layer-by-layer increment in the airflow temperature was done, which improved the performance of the FFF PEEK printing process for large-sized cranial implants. We then evaluated the potential clinical reliability of the POC manufactured 3D printed PEEK PSIs for cranial reconstruction by quantitative assessment of geometric, morphological, and biomechanical characteristics. It was noticed that the 3D printed customized cranial implants had high dimensional accuracy and repeatability, displaying clinically acceptable morphologic similarity concerning fit and contours continuity. However, the tested cranial implants had variable peak load values with discrete fracture patterns from a biomechanical standpoint. The implants with the highest peak load had a strong bonding with uniform PEEK fusion and interlayer connectivity, while air gaps and infill fusion lines were observed in implants with the lowest strength. The results of this preclinical study were in line with the clinical applicability of cranial implants; however, the biomechanical attribute can be further improved. It was noticed that each patient-specific reconstructive implant required a different set of manufacturing parameters. This was ascertained by manufacturing a porous PEEK patient-specific orbital implant. We evaluated the FFF 3D printed PEEK orbital mesh customized implants with a metric considering the design variants, biomechanical, and morphological parameters. We then studied the performance of the implants as a function of varying thicknesses and porous design constructs through a finite element (FE) based computational model and a decision matrix based statistical approach. The maximum stress values achieved in our results predicted the high durability of the implants. In all the implant profile configurations, the maximum deformation values were under one-tenth of a millimeter (mm) domain. The circular patterned design variant implant revealed the best performance score. The study further demonstrated that compounding multi-design computational analysis with 3D printing can be beneficial for the optimal restoration of the orbital floor. In the framework of the current thesis, the potential clinical application of material extrusion-based 3D printing for PEEK customized implants at the POC was demonstrated. We implemented clinical experience and engineering principles to generate a technical roadmap from preoperative medical imaging datasets to virtual surgical planning, computer-aided design models of various reconstructive implant variants, to the fabrication of PEEK PSIs using FFF 3D printing technology. The integration of 3D printing PEEK implants at the POC entails numerous benefits, including a collaborative team approach, quicker turnaround time of customized implants, support in pre-surgical and intraoperative planning, improved patient outcomes, and decreased overall healthcare cost. We believe that FFF 3D printing of customized PEEK implants could become an integral part of the hospitals and holds potential for various reconstructive surgery applications

Template-based reverse engineering of parametric CAD models from point clouds

openEven if many Reverse Engineering techniques exist to reconstruct real objects in 3D, very few are able to deal directly and efficiently with the reconstruction of editable CAD models of assemblies of mechanical parts that can be used in the stages of Product Development Processes (PDP). In the absence of suitable segmentation tools, these approaches struggle to identify and reconstruct model the different parts that make up the assembly. The thesis aims to develop a new Reverse Engineering technique for the reconstruction of editable CAD models of mechanical parts’ assemblies. The originality lies in the use of a Simulated Annealing-based fitting technique optimization process that leverages a two-level filtering able to capture and manage the boundaries of the parts’ geometries inside the overall point cloud to allow for interface detection and local fitting of a part template to the point cloud. The proposed method uses various types of data (e.g. clouds of points, CAD models possibly stored in database together with the associated best parameter configurations for the fitting process). The approach is modular and integrates a sensitivity analysis to characterize the impact of the variations of the parameters of a CAD model on the evolution of the deviation between the CAD model itself and the point cloud to be fitted. The evaluation of the proposed approach is performed using both real scanned point clouds and as-scanned virtually generated point clouds which incorporate several artifacts that could appear with a real scanner. Results cover several Industry 4.0 related application scenarios, ranging from the global fitting of a single part to the update of a complete Digital Mock-Up embedding assembly constraints. The proposed approach presents good capacities to help maintaining the coherence between a product/system and its digital twin.openXXXIII CICLO - INGEGNERIA MECCANICA, ENERGETICA E GESTIONALE - Meccanica, misure e robotica01/A3 - ANALISI MATEMATICA, PROBABILITA' E STATISTICA MATEMATICA01/B1 - INFORMATICA09/B2 - IMPIANTI INDUSTRIALI MECCANICIShah, GHAZANFAR AL