Advanced Applications of Rapid Prototyping Technology in Modern Engineering

Rapid prototyping (RP) technology has been widely known and appreciated due to its flexible and customized manufacturing capabilities. The widely studied RP techniques include stereolithography apparatus (SLA), selective laser sintering (SLS), three-dimensional printing (3DP), fused deposition modeling (FDM), 3D plotting, solid ground curing (SGC), multiphase jet solidification (MJS), laminated object manufacturing (LOM). Different techniques are associated with different materials and/or processing principles and thus are devoted to specific applications. RP technology has no longer been only for prototype building rather has been extended for real industrial manufacturing solutions. Today, the RP technology has contributed to almost all engineering areas that include mechanical, materials, industrial, aerospace, electrical and most recently biomedical engineering. This book aims to present the advanced development of RP technologies in various engineering areas as the solutions to the real world engineering problems

Automatic Mesh Repair and Optimization for Quality Mesh Generation

Ph.DDOCTOR OF PHILOSOPH

Applied AI/ML for automatic customisation of medical implants

Most knee replacement surgeries are performed using ‘off-the-shelf’ implants, supplied with a set number of standardised sizes. X-rays are taken during pre-operative assessment and used by clinicians to estimate the best options for patients. Manual templating and implant size selection have, however, been shown to be inaccurate, and frequently the generically shaped products do not adequately fit patients’ unique anatomies. Furthermore, off-the-shelf implants are typically made from solid metal and do not exhibit mechanical properties like the native bone. Consequently, the combination of these factors often leads to poor outcomes for patients. Various solutions have been outlined in the literature for customising the size, shape, and stiffness of implants for the specific needs of individuals. Such designs can be fabricated via additive manufacturing which enables bespoke and intricate geometries to be produced in biocompatible materials. Despite this, all customisation solutions identified required some level of manual input to segment image files, identify anatomical features, and/or drive design software. These tasks are time consuming, expensive, and require trained resource. Almost all currently available solutions also require CT imaging, which adds further expense, incurs high levels of potentially harmful radiation, and is not as commonly accessible as X-ray imaging. This thesis explores how various levels of knee replacement customisation can be completed automatically by applying artificial intelligence, machine learning and statistical methods. The principal output is a software application, believed to be the first true ‘mass-customisation’ solution. The software is compatible with both 2D X-ray and 3D CT data and enables fully automatic and accurate implant size prediction, shape customisation and stiffness matching. It is therefore seen to address the key limitations associated with current implant customisation solutions and will hopefully enable the benefits of customisation to be more widely accessible.Open Acces

Three Dimensional Nonlinear Statistical Modeling Framework for Morphological Analysis

This dissertation describes a novel three-dimensional (3D) morphometric analysis framework for building statistical shape models and identifying shape differences between populations. This research generalizes the use of anatomical atlases on more complex anatomy as in case of irregular, flat bones, and bones with deformity and irregular bone growth. The foundations for this framework are: 1) Anatomical atlases which allow the creation of homologues anatomical models across populations; 2) Statistical representation for output models in a compact form to capture both local and global shape variation across populations; 3) Shape Analysis using automated 3D landmarking and surface matching. The proposed framework has various applications in clinical, forensic and physical anthropology fields. Extensive research has been published in peer-reviewed image processing, forensic anthropology, physical anthropology, biomedical engineering, and clinical orthopedics conferences and journals. The forthcoming discussion of existing methods for morphometric analysis, including manual and semi-automatic methods, addresses the need for automation of morphometric analysis and statistical atlases. Explanations of these existing methods for the construction of statistical shape models, including benefits and limitations of each method, provide evidence of the necessity for such a novel algorithm. A novel approach was taken to achieve accurate point correspondence in case of irregular and deformed anatomy. This was achieved using a scale space approach to detect prominent scale invariant features. These features were then matched and registered using a novel multi-scale method, utilizing both coordinate data as well as shape descriptors, followed by an overall surface deformation using a new constrained free-form deformation. Applications of output statistical atlases are discussed, including forensic applications for the skull sexing, as well as physical anthropology applications, such as asymmetry in clavicles. Clinical applications in pelvis reconstruction and studying of lumbar kinematics and studying thickness of bone and soft tissue are also discussed

Segmentierung medizinischer Bilddaten und bildgestützte intraoperative Navigation

Die Entwicklung von Algorithmen zur automatischen oder semi-automatischen Verarbeitung von medizinischen Bilddaten hat in den letzten Jahren mehr und mehr an Bedeutung gewonnen. Das liegt zum einen an den immer besser werdenden medizinischen Aufnahmemodalitäten, die den menschlichen Körper immer feiner virtuell abbilden können. Zum anderen liegt dies an der verbesserten Computerhardware, die eine algorithmische Verarbeitung der teilweise im Gigabyte-Bereich liegenden Datenmengen in einer vernünftigen Zeit erlaubt. Das Ziel dieser Habilitationsschrift ist die Entwicklung und Evaluation von Algorithmen für die medizinische Bildverarbeitung. Insgesamt besteht die Habilitationsschrift aus einer Reihe von Publikationen, die in drei übergreifende Themenbereiche gegliedert sind: -Segmentierung medizinischer Bilddaten anhand von vorlagenbasierten Algorithmen -Experimentelle Evaluation quelloffener Segmentierungsmethoden unter medizinischen Einsatzbedingungen -Navigation zur Unterstützung intraoperativer Therapien Im Bereich Segmentierung medizinischer Bilddaten anhand von vorlagenbasierten Algorithmen wurden verschiedene graphbasierte Algorithmen in 2D und 3D entwickelt, die einen gerichteten Graphen mittels einer Vorlage aufbauen. Dazu gehört die Bildung eines Algorithmus zur Segmentierung von Wirbeln in 2D und 3D. In 2D wird eine rechteckige und in 3D eine würfelförmige Vorlage genutzt, um den Graphen aufzubauen und das Segmentierungsergebnis zu berechnen. Außerdem wird eine graphbasierte Segmentierung von Prostatadrüsen durch eine Kugelvorlage zur automatischen Bestimmung der Grenzen zwischen Prostatadrüsen und umliegenden Organen vorgestellt. Auf den vorlagenbasierten Algorithmen aufbauend, wurde ein interaktiver Segmentierungsalgorithmus, der einem Benutzer in Echtzeit das Segmentierungsergebnis anzeigt, konzipiert und implementiert. Der Algorithmus nutzt zur Segmentierung die verschiedenen Vorlagen, benötigt allerdings nur einen Saatpunkt des Benutzers. In einem weiteren Ansatz kann der Benutzer die Segmentierung interaktiv durch zusätzliche Saatpunkte verfeinern. Dadurch wird es möglich, eine semi-automatische Segmentierung auch in schwierigen Fällen zu einem zufriedenstellenden Ergebnis zu führen. Im Bereich Evaluation quelloffener Segmentierungsmethoden unter medizinischen Einsatzbedingungen wurden verschiedene frei verfügbare Segmentierungsalgorithmen anhand von Patientendaten aus der klinischen Routine getestet. Dazu gehörte die Evaluierung der semi-automatischen Segmentierung von Hirntumoren, zum Beispiel Hypophysenadenomen und Glioblastomen, mit der frei verfügbaren Open Source-Plattform 3D Slicer. Dadurch konnte gezeigt werden, wie eine rein manuelle Schicht-für-Schicht-Vermessung des Tumorvolumens in der Praxis unterstützt und beschleunigt werden kann. Weiterhin wurde die Segmentierung von Sprachbahnen in medizinischen Aufnahmen von Hirntumorpatienten auf verschiedenen Plattformen evaluiert. Im Bereich Navigation zur Unterstützung intraoperativer Therapien wurden Softwaremodule zum Begleiten von intra-operativen Eingriffen in verschiedenen Phasen einer Behandlung (Therapieplanung, Durchführung, Kontrolle) entwickelt. Dazu gehört die erstmalige Integration des OpenIGTLink-Netzwerkprotokolls in die medizinische Prototyping-Plattform MeVisLab, die anhand eines NDI-Navigationssystems evaluiert wurde. Außerdem wurde hier ebenfalls zum ersten Mal die Konzeption und Implementierung eines medizinischen Software-Prototypen zur Unterstützung der intraoperativen gynäkologischen Brachytherapie vorgestellt. Der Software-Prototyp enthielt auch ein Modul zur erweiterten Visualisierung bei der MR-gestützten interstitiellen gynäkologischen Brachytherapie, welches unter anderem die Registrierung eines gynäkologischen Brachytherapie-Instruments in einen intraoperativen Datensatz einer Patientin ermöglichte. Die einzelnen Module führten zur Vorstellung eines umfassenden bildgestützten Systems für die gynäkologische Brachytherapie in einem multimodalen Operationssaal. Dieses System deckt die prä-, intra- und postoperative Behandlungsphase bei einer interstitiellen gynäkologischen Brachytherapie ab

SCAFFOLD DESIGN PARAMETERS TO STIMULATE THE OSTEOGENIC SIGNAL EXPRESSION FOR BONE TISSUE ENGINEERING APPLICATIONS

The fundamental components of bone tissue engineering are (a) progenitor cells which subsequently express tissue matrix, (b) scaffolds which can act as temporary frameworks to support bone growth, and (c) growth factors to induce osteoblast regeneration. A variety of growth factors are involved during the differentiation cascade and these chemical and biological signals dynamically interact with cell populations to facilitate the differentiation. Therefore, enhanced expression of endogenous growth factor genes might facilitate abundant existence of growth factors in the surrounding microenvironment, stimulate the osteogenic differentiation of progenitor cell population, and finally induce bone regeneration. This work is focused on the augmentation of osteogenic signal expressions to stimulate the downstream differentiation of transplanted bone marrow stromal cells (BMSCs) population through the optimization of a variety of properties of three dimensional (3D) biodegradable poly(propylene fumarate) (PPF) scaffold. Changes in the microenvironment of cell population would affect the responses of localized cell population and the manipulated scaffold properties might be associated with induction of endogenous osteogenic signal expressions. First, the effect of cell-to-cell paracrine signaling distance, which can by modulated by initial cell seeding density, on the osteogenic signal expressions and osteoblastic differentiation of BMSCs on 2D PPF disks was investigated. Next, in order to investigate the improvement of the 3D macroporous PPF scaffold by the incorporation with nanoparticle filler materials, PPF/hydroxyapatite (HA) nanocomposite scaffolds were fabricated. The effect of HA content and initial cell seeding density on the osteogenic signal expression in 3D porous system was then determined. Finally, the incorporation of diethyl dumarate (DEF) with PPF was tested based on the photocrosslinking characteristics of PPF/DEF composite material with increased mechanical properties. The effect of two scaffold design parameters including the stiffness by modulating the DEF content as well as the pore size of porous scaffold on the signal expression and downstream osteoblastic differentiation was investigated. In addition, the feasibility of PPPF/DEF materials for stereolithographical fabrication was also tested in this work. Controlling these construction parameters to optimize engineered bone substitutes could affect various cellular functions of attachment, proliferation, signal expression, and differentiation. This research provided the insight of stimulation of the expression of target endogenous genes to induce the osteogenic differentiation and bone regeneration as well as the fabrication of improved bone substitute implant materials which is clinically applicable

CT Scanning

Since its introduction in 1972, X-ray computed tomography (CT) has evolved into an essential diagnostic imaging tool for a continually increasing variety of clinical applications. The goal of this book was not simply to summarize currently available CT imaging techniques but also to provide clinical perspectives, advances in hybrid technologies, new applications other than medicine and an outlook on future developments. Major experts in this growing field contributed to this book, which is geared to radiologists, orthopedic surgeons, engineers, and clinical and basic researchers. We believe that CT scanning is an effective and essential tools in treatment planning, basic understanding of physiology, and and tackling the ever-increasing challenge of diagnosis in our society

Non-destructive quantification of tissue scaffolds and augmentation implants using X-ray microtomography

A three dimensional (3D), interconnected, porous structure is essential for bone tissue engineering scaffolds and skeletal augmentation implants. Current methods of characterising these structures, however, are limited to average properties such as percentage porosity. More accurate quantitative properties, such as pore and interconnect size distributions, are required. Once measured, these parameters need to be correlated to tissue regeneration and integration criteria, including solute transport, blood vessel regeneration, bone ingrowth, and mechanical properties. Ideally, these techniques would work in vitro and in vivo, and hence allow evaluation of osteoconduction and osseointegration after implantation. This thesis will focus on developing and applying algorithms for use with X-ray microtomography (micro-CT or μCT) which can non-destructively image internal structure at the micron scale. The technique will be demonstrated on two separate materials: bioactive glass scaffolds and titanium (Ti) augmentation devices. Using the developed techniques, the structural and compositional evolutions of bioactive glass scaffolds in a simulated body fluid (SBF) flow environment were quantified using micro-CT scans taken at different dissolution stages. Results show that 70S30C bioactive scaffolds retain favourable 3D structures during a 28 d dissolution experiment, with a modal equivalent pore diameter of 682 μm staying unchanged, and a modal equivalent interconnect diameter decreasing from 252 μm to 209 μm. The techniques were then applied to porous Ti augmentation scaffolds. These scaffolds, produced by selective laser melting have very different pore networks with graded randomness and unit size. They present new challenges when applying the developed micro-CT quantification techniques. Using a further adapted methodology, the interconnecting pore sizes, strut thickness, and surface roughness were measured. This demonstrated the robustness of the methodologies and their applicability to a range of tissue scaffolds and augmentation devices

Development of procedures for the design, optimization and manufacturing of customized orthopaedic and trauma implants: Geometrical/anatomical modelling from 3D medical imaging

Tese de Doutoramento (Programa Doutoral em Engenharia Biomédica)The introduction of imaging techniques in 1970 is one of the most relevant historical milestones in modern medicine. Medical imaging techniques have dramatically changed our understanding of the Human anatomy and physiology. The ability to non-invasively extract visual information allowed, not only the three-dimensional representation of the internal organs and musculo-skeletal system, but also the simulation of surgical procedures, the execution of computer aided surgeries, the development of more accurate biomechanical models, the development of custom-made implants, among others. The combination of the most advanced medical imaging systems with the most advanced CAD and CAM techniques, may allow the development of custom-made implants that meet patient-speci c traits. The geometrical and functional optimization of these devices may increase implant life-expectancy, especially in patients with marked deviations from the anatomical standards. In the implant customization protocol from medical image data, there are several steps that need to be followed in a sequential way, namely: Medical Image Processing and Recovering; Accurate Image Segmentation and 3D Surface Model Generation; Geometrical Customization based on CAD and CAE techniques; FEA Optimization of the Implant Geometry; and Manufacturing using CAD-CAM Technologies. This work aims to develop the necessary procedures for custom implant development from medical image data. This includes the extraction of highly accurate three-dimensional representation of the musculo-skeletal system from the Computed Tomography imaging, and the development of customized implants, given the speci c requirements of the target anatomy, and the applicable best practices found in the literature. A two-step segmentation protocol is proposed. In the rst step the region of interest is pre-segmented in order to obtain a good approximation to the desired geometry. Next, a fully automatic segmentation re nement is applied to obtain a more accurate representation of the target domain. The re nement step is composed by several sub-steps, more precisely, the recovery of the original image, considering the limiting resolution of the imaging system; image cropping; image interpolation; and segmentation re nement over the up-sampled domain. Highly accurate segmentations of the target domain were obtained with the proposed pipeline. The limiting factor to the accurate description of the domain accuracy is the image acquisition process, rather the following image processing, segmentation and surface meshing steps. The new segmentation pipeline was used in the development of three tailor-made implants, namely, a tibial nailing system, a mandibular implant, and a Total Hip Replacement system. Implants optimization is carried with Finite Element Analysis, considering the critical loading conditions that may be applied to each implant in working conditions. The new tibial nailing system is able of sustaining critical loads without implant failure; the new mandibular endoprosthesis that allows the recovery of the natural stress and strain elds observed in intact mandibles; and the Total Hip Replacement system that showed comparable strain shielding levels as commercially available stems. In summary, in the present thesis the necessary procedures for custom implant design are investigated, and new algorithms proposed. The guidelines for the characterization of the image acquisition, image processing, image segmentation and 3D reconstruction are presented and discussed. This new image processing pipeline is applied and validated in the development of the three abovementioned customized implants, for di erent medical applications and that satisfy speci c anatomical needs.Um dos principais marcos da história moderna da medicina e a introdução da imagem médica, em meados da década de 1970. As tecnologias de imagem permitiram aumentar e potenciar o nosso conhecimento acerca da anatomia e fisiologia do corpo Humano. A capacidade de obter informação imagiológica de forma não invasiva permitiu, não são a representação tridimensional de órgãos e do sistema músculo-esquelético, mas também a simulação de procedimentos cirúrgicos, a realização de cirurgias assistidas por computador, a criação de modelos biomecânicos mais realistas, a criação de implantes personalizados, entre outros. A conjugação dos sistemas mais avançados de imagem medica com as técnicas mais avançadas de modelação e maquinagem, pode permitir o desenvolvimento de implantes personalizados mais otimizados, que vão de encontro as especificidades de cada paciente. Por sua vez, a otimização geométrica e biomecânica destes dispositivos pode permitir, quer o aumento da sua longevidade, quer o tratamento de pessoas com estruturas anatómicas que se afastam dos padrões normais. O processo de modelação de implantes a partir da imagem medica passa por um conjunto de procedimentos a adotar, sequencialmente, ate ao produto final, a saber: Processamento e Recuperação de Imagem; Segmentação de Imagem e Reconstrução tridimensional da Região de Interesse; Modelação Geométrica do Implante; Simulação Numérica para a Otimização da Geometria; a Maquinagem do Implante. Este trabalho visa o desenvolvimento dos procedimentos necessários para a criação de implantes personalizados a partir da imagem medica, englobando a extração de modelos ósseos geométricos rigorosos a partir de imagens de Tomografia Computorizada e, a partir desses modelos, desenvolver implantes personalizados baseados nas melhores praticas existentes na literatura e que satisfaçam as especificidades da anatomia do paciente. Assim, apresenta-se e discute-se um novo procedimento de segmentação em dois passos. No primeiro e feita uma pre-segmentação que visa obter uma aproximação iniciala região de interesse. De seguida, um procedimento de refinamento da segmentação totalmente automático e aplicada a segmentação inicial para obter uma descrição mais precisa do domínio de interesse. O processo de refinamento da segmentação e constituído por vários procedimentos, designadamente: recuperação da imagem original, tendo em consideração a resolução limitante do sistema de imagem; o recorte da imagem na vizinhança da região pre-segmentada; a interpolação da região de interesse; e o refinamento da segmentação aplicando a técnica de segmentação Level-Sets sobre o domínio interpolado. O procedimento de segmentação permitiu extrair modelos extremamente precisos a partir da informação imagiológica. Os resultados revelam que o fator limitante a descrição do domínio e o processo de aquisição de imagem, em detrimento dos diversos passos de processamento subsequentes. O novo protocolo de segmentação foi utilizado no desenvolvimento de três implantes personalizados, a saber: um sistema de fixação interna para a tíbia; um implante mandibular; e um sistema para a Reconstrução Total da articulação da Anca. A otimização do comportamento mecânico dos implantes foi feita utilizado o Método dos Elementos Finitos, tendo em conta os carregamentos críticos a que estes podem estar sujeitos durante a sua vida útil. O sistema de fixação interna para a tíbia e capaz de suportar os carregamentos críticos, sem que a sua integridade mecânica seja comprometida; o implante mandibular permite recuperar os campos de tensão e deformação observados em mandíbulas intactas; e a Prótese Total da Anca apresenta níveis de strain shielding ao longo do fémur proximal comparáveis com os níveis observados em dispositivos comercialmente disponíveis. Em suma, nesta tese de Doutoramento são investigados e propostos novos procedimentos para o projeto de implantes feitos por medida. São apresentadas e discutidas as linhas orientadoras para a caracterização precisa do sistema de aquisição de imagem, para o processamento de imagem, para a segmentação, e para a reconstrução 3D das estruturas anatómicas a partir da imagem medica. Este conjunto de linhas orientadoras é aplicado e validado no desenvolvimento de três implantes personalizados, citados anteriormente, para aplicações médicas distintas e que satisfazem as necessidades anatómicas específicas de cada paciente.Fundação para a Ciência e Tecnologia (FCT