EXPERIMENTAL EVALUATION OF HIERARCHICAL FUNCTIONALLY GRADED LATTICES USING DIGITAL IMAGE CORRELATION AND MICRO-CT

Hierarchical meta-materials based on functionally-graded lattices (FGLs) have the benefit of customizable material properties. However, the effects of sharp transitions on the effective properties of FGLs have yet to be evaluated. This experimental study focused on characterizing the compressive properties of hierarchical FGLs built with smooth or sharp gradings. A total of 12 samples were 3D-printed in Ti-6Al-4V alloy and tested in axial compressive loading. Digital image correlation (DIC) was used to measure displacements and deformations. The 3D-printing quality of FGLs was also evaluated by micro-CT imaging of 5 samples. The results showed that the cross-sectional areas of struts in FGLs with sharp transitions were 26% smaller than uniform lattices and FGLs with smooth transitions. Compression testing also confirmed a lower average elastic modulus in FGLs with sharp gradings. These results will provide insights for incorporating adjustment factors to account for the loss of strength in FGLs.Mechanical Engineerin

A computational method for estimating trunk muscle activations during gait using lower extremity muscle synergies

One of the surgical treatments for pelvic sarcoma is the restoration of hip function with a custom pelvic prosthesis after cancerous tumor removal. The orthopedic oncologist and orthopedic implant company must make numerous often subjective decisions regarding the design of the pelvic surgery and custom pelvic prosthesis. Using personalized musculoskeletal computer models to predict post-surgery walking function and custom pelvic prosthesis loading is an emerging method for making surgical and custom prosthesis design decisions in a more objective manner. Such predictions would necessitate the estimation of forces generated by muscles spanning the lower trunk and all joints of the lower extremities. However, estimating trunk and leg muscle forces simultaneously during walking based on electromyography (EMG) data remains challenging due to the limited number of EMG channels typically used for measurement of leg muscle activity. This study developed a computational method for estimating unmeasured trunk muscle activations during walking using lower extremity muscle synergies. To facilitate the calibration of an EMG-driven model and the estimation of leg muscle activations, EMG data were collected from each leg. Using non-negative matrix factorization, muscle synergies were extracted from activations of leg muscles. On the basis of previous studies, it was hypothesized that the time-varying synergy activations were shared between the trunk and leg muscles. The synergy weights required to reconstruct the trunk muscle activations were determined through optimization. The accuracy of the synergy-based method was dependent on the number of synergies and optimization formulation. With seven synergies and an increased level of activation minimization, the estimated activations of the erector spinae were strongly correlated with their measured activity. This study created a custom full-body model by combining two existing musculoskeletal models. The model was further modified and heavily personalized to represent various aspects of the pelvic sarcoma patient, all of which contributed to the estimation of trunk muscle activations. This proposed method can facilitate the prediction of post-surgery walking function and pelvic prosthesis loading, as well as provide objective evaluations for surgical and prosthesis design decisions

Experimental Evaluation of the Effects of Discrete-Grading-Induced Discontinuities on the Material Properties of Functionally Graded Ti-6Al-4V Lattices

In this study, we compared the material properties of linearly and sharply graded Ti6Al4V additively manufactured samples to investigate whether the more severe discontinuities caused by sharp grading can reduce performance. We performed compression testing with digital image correlation (DIC) in two loading directions for each grading design to simulate iso-stress and iso-strain conditions. We extracted the elastic stiffness, yield strength, yield strain, and energy absorption capacity of each sample. In addition, we used micro-computed tomography (micro-CT) imaging to examine the printing quality and dimensional accuracy. We found that sharply graded struts have a 12.95% increase in strut cross-sectional areas, whereas linearly graded struts produced an average of 49.24% increase compared to design. However, sharply graded and linearly graded FGL samples do not have statistically significant differences in elastic stiffness and yield strength. For the iso-strain condition, the average DIC-corrected stiffnesses for linearly and sharply graded samples were 6.15 GPa and 5.43 GPa, respectively (p = 0.4466), and the yield stresses were 290.4 MPa and 291.2 MPa, respectively (p = 0.5734). Furthermore, we confirmed different types of printing defects using micro-CT, including defective pores and disconnected struts. These results suggest that the loss of material properties caused by manufacturing defects outweighs the adverse effects of discrete-grading-induced discontinuities