Design and 3D printing customized guides for orthopaedic surgery – lessons learned

2018 ◽  
Vol 24 (5) ◽  
pp. 901-913 ◽  
Author(s):  
Diana Popescu ◽  
Dan Laptoiu ◽  
Rodica Marinescu ◽  
Iozefina Botezatu
Keyword(s):  
3D Printing ◽  
Case Studies ◽  
Orthopaedic Surgery ◽  
Development Process ◽  
Lessons Learned ◽  
Patient Specific ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Fused Deposition ◽  
Surgical Guides

Purpose This paper aims to fill a research gap by presenting design and 3D printing guidelines and considerations which apply to the development process of patient-specific osteotomy guides for orthopaedic surgery. Design/methodology/approach Analysis of specific constraints related to patient-specific surgical guides design and 3D printing, lessons learned during the development process of osteotomy guides for orthopaedic surgery, literature review of recent studies in the field and data gathered from questioning a group of surgeons for capturing their preferences in terms of surgical guides design corresponding to precise functionality (materializing cutting trajectories, ensuring unique positioning and stable fixation during surgery), were all used to extract design recommendations. Findings General design rules for patient-specific osteotomy guides were inferred from examining each step of the design process applied in several case studies in relation to how these guides should be designed to fulfill medical and manufacturing (fused deposition modelling process) constraints. Literature was also investigated for finding other information than the simple reference that the surgical guide is modelled as negative of the bone. It was noticed that literature is focussed more on presenting and discussing medical issues and on assessing surgical outcomes, but hardly at all on guides’ design and design for additive manufacturing aspects. Moreover, surgeons’ opinion was investigated to collect data on different design aspects, as well as interest and willingness to use such 3D-printed surgical guides in training and surgery. Practical implications The study contains useful rules and recommendations for engineers involved in designing and 3D printing patient-specific osteotomy guides. Originality/value A synergetic approach to identify general rules and recommendations for the patient-specific surgical guides design is presented. Specific constraints are identified and analysed using three case studies of wrist, femur and foot osteotomies. Recent literature is reviewed and surgeons’ opinion is investigated.

Use of polymer concrete for large-scale 3D printing

2021 ◽  
Vol 27 (3) ◽  
pp. 465-474
Author(s):  
Martin Krčma ◽  
David Škaroupka ◽  
Petr Vosynek ◽  
Tomáš Zikmund ◽  
Jozef Kaiser ◽  
...  
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Mechanical Performance ◽  
Construction Material ◽  
Polymer Concrete ◽  
Fused Deposition Modelling ◽  
Cast State ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

scholarly journals Three-dimensional Printing Versus Conventional Machining in the Creation of a Meatal Urethral Dilator: a Cost and Mechanical Strength Analysis

2020 ◽  
Author(s):  
Michael Yue-Cheng Chen ◽  
Jacob Skewes ◽  
Ryan Daley ◽  
Maria Ann Woodruff ◽  
Nicholas John Rukin
Keyword(s):  
3D Printing ◽  
Three Dimensional ◽  
Patient Specific ◽  
Strength Analysis ◽  
Fused Deposition Modelling ◽  
3D Printer ◽  
Current Time ◽  
Fused Deposition ◽  
3D Printed ◽  
Conventional Machining

Abstract BackgroundThree-dimensional (3D) printing is a promising technology but the limitations are often poorly understood. We compare different 3D printingmethods with conventional machining techniques in manufacturing meatal urethral dilators which were recently removed from the Australian market. MethodsA prototype dilator was 3D printed vertically orientated on a low cost fused deposition modelling (FDM) 3D printer in polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). It was also 3D printed horizontally orientated in ABS on a high-end FDM 3D printer with soluble support material, as well as on a SLS 3D printer in medical nylon. The dilator was also machined in stainless steel using a lathe. All dilators were tested mechanically in a custom rig by hanging calibrated weights from the handle until the dilator snapped. ResultsThe horizontally printed ABS dilator experienced failure at a greater load than the vertically printed PLA and ABS dilators respectively (503g vs 283g vs 163g, p < 0.001). The SLS nylon dilator and machined steel dilator did not fail. The steel dilator is most expensive with a quantity of five at 98 USD each, but this decreases to 30 USD each for a quantity of 1000. In contrast, the cost for the SLS dilator is 33 USD each for five and 27 USD each for 1000. ConclusionsAt the current time 3D printing is not a replacement for conventional manufacturing. 3D printing is best used for patient-specific parts, prototyping or manufacturing complex parts that have additional functionality that cannot otherwise beachieved.

Impact of 3D-printing structure on the tribological properties of polymers

2020 ◽  
Vol 72 (6) ◽  
pp. 811-818 ◽  
Author(s):  
Muammel M. Hanon ◽  
Róbert Marczis ◽  
László Zsidai
Keyword(s):  
3D Printing ◽  
Tribological Properties ◽  
Future Research ◽  
Fused Deposition Modelling ◽  
Wear Depth ◽  
Printing Process ◽  
Content Type ◽  
Fused Deposition ◽  
Polylactide Acid ◽  
The Impact

Purpose The purpose of this paper is to examine the impact of three-dimensional (3D)-printing process settings (particularly print orientation) on the tribological properties of different polymers. Design/methodology/approach In this study, fused deposition modelling 3D-printing technology was used for fabricating the specimens. To evaluate the influence of print orientation, the test pieces were manufactured horizontally (X) and vertically (Z). The tribological properties of various printed polymers, which are polylactide acid, high tensile/high temperature-polylactide acid and polyethylene terephthalate-glycol have been studied. The tribological tests have been carried out under reciprocating sliding and dry condition. Findings The results show that the presence of various orientations during the 3D-printing process makes a difference in the coefficient of friction and the wear depth values. Findings suggest that printing structure in the horizontal orientation (X) assists in reducing friction and wear. Originality/value To date, there has been very limited research on the tribology of objects produced by 3D printing. This work was made as an attempt to pave the way for future research on the science of tribology of 3D-printed polymers.

scholarly journals Modern Applications of 3D Printing: The Case of an Artificial Ear Splint Model

2021 ◽  
Vol 4 (3) ◽  
pp. 54
Author(s):  
Athanasios Argyropoulos ◽  
Pantelis N. Botsaris
Keyword(s):  
3D Printing ◽  
Three Dimensional ◽  
Shape Preservation ◽  
Patient Specific ◽  
Fused Deposition Modelling ◽  
Comprehensive Overview ◽  
Protruding Ears ◽  
Fused Deposition ◽  
Custom Made ◽  
Wide Range

Three-dimensional (3D) printing is a leading manufacturing technique in the medical field. The constantly improving quality of 3D printers has revolutionized the approach to new challenges in medicine for a wide range of applications including otoplasty, medical devices, and tissue engineering. The aim of this study is to provide a comprehensive overview of an artificial ear splint model applied to the human auricle for the treatment of stick-out protruding ears. The deformity of stick-out protruding ears remains a significant challenge, where the complex and distinctive shape preservation are key factors. To address this challenge, we have developed a protocol that involves photogrammetry techniques, reverse engineering technologies, a smart prototype design, and 3D printing processes. Specifically, we fabricated a 3D printed ear splint model via fused deposition modelling (FDM) technology by testing two materials, a thermoplastic polyester elastomer material (Z-Flex) and polycaprolactone (PCL 100). Our strategy affords a custom-made and patient-specific artificial ear aligner with mechanical properties that ensures sufficient preservation of the auricular shape by applying a force on the helix and antihelix and enables the ears to pin back to the head.

FDM 3D printing method utility assessment in small RC aircraft design

2019 ◽  
Vol 91 (6) ◽  
pp. 865-872 ◽  
Author(s):  
Igor Skawiński ◽  
Tomasz Goetzendorf-Grabowski
Keyword(s):  
3D Printing ◽  
Aircraft Design ◽  
Cost Effective ◽  
Fused Deposition Modelling ◽  
Thin Wall ◽  
Good Reliability ◽  
Content Type ◽  
Fused Deposition ◽  
Wall Structures ◽  
3D Printed

Purpose The purpose of this paper is to investigate the possibility of manufacturing fused deposition modelling (FDM) 3D printed structures such as wings or fuselages for small remote control (RC) air craft and mini unmaned aerial vehicles (UAVs). Design/methodology/approach Material tests, design assumptions and calculations were verified by designing and manufacturing a small radio-controlled motor-glider using as many printed parts as possible and performing test flights. Findings It is possible to create an aircraft with good flight characteristics using FDM 3D printed parts. Current level of technology allows for reasonably fast manufacturing of 3D printed aircraft with good reliability and high success ratio of prints; however, only some of the materials are suitable for printing thin wall structures such as wings. Practical implications The paper proves that apart from currently popular small RC aircraft structural materials such as composites, wood and foam, there is also printed plastic. Moreover, 3D printing is highly competitive in some aspects such as first unit production time or production cost. Originality/value The presented manufacturing technique can be useful for quick and cost-effective creating scale prototypes of the aircraft for performing test flights.

Accuracy of 3D printed guide for orbital implant

2020 ◽  
Vol 26 (8) ◽  
pp. 1363-1370
Author(s):  
Jaeyoung Kwon ◽  
Guk Bae Kim ◽  
Sunah Kang ◽  
Younghwa Byeon ◽  
Ho-Seok Sa ◽  
...  
Keyword(s):  
3D Printing ◽  
Patient Specific ◽  
Orbital Fracture ◽  
Uv Curable ◽  
Content Type ◽  
Orbital Implant ◽  
Surgical Guides ◽  
3D Printed ◽  
The Mean ◽  
Mean Differences

Purpose Extrinsic trauma to the orbit may cause a blowout or orbital fracture, which often requires surgery for reconstruction of the orbit and repositioning of the eyeball with an implant. Post-operative complications, however, are high with the most frequent cause of complications being a mismatch of the position and shape of the implant and fracture. These mismatches may be reduced by computed tomography (CT) based modeling and three-dimensional (3D) printed guide. Therefore, the aim of this study is to propose and evaluate a patient-specific guide to shape an orbital implant using 3D printing. Design/methodology/approach Using CT images of a patient, an orbital fracture can be modeled to design an implant guide for positioning and shaping of the surface and boundaries of the implant. The guide was manufactured using UV curable plastic at 0.032 mm resolution by a 3D printer. The accuracy of this method was evaluated by micro-CT scanning of the surgical guides and shaping implants. Findings The length and depth of the 3D model, press-compressed and decompressed implants were compared. The mean differences in length were 0.67 ± 0.38 mm, 0.63 ± 0.28 mm and 0.10 ± 0.10 mm, and the mean differences in depth were 0.64 ± 0.37 mm, 1.22 ± 0.56 mm and 0.57 ± 0.23 mm, respectively. Statistical evaluation was performed with a Bland-Altman plot. Originality/value This study suggests a patient-specific guide to shape an orbital implant using 3D printing and evaluate the guiding accuracy of the implant versus the planned model.

scholarly journals Advancing biomaterials towards biological complexity

2018 ◽  
Vol 40 (1) ◽  
pp. 16-19
Author(s):  
Alexandra Pastino ◽  
Joseph Steele ◽  
Joachim Kohn
Keyword(s):  
3D Printing ◽  
Structural Complexity ◽  
Biologically Active ◽  
Patient Specific ◽  
Fused Deposition Modelling ◽  
Biological Complexity ◽  
Active Materials ◽  
Fused Deposition ◽  
Single Technique ◽  
Made In

3D printing has the potential for on-demand, patient-specific devices with high structural complexity. However, the tools and biomaterials most widely available for 3D printing are largely limited to fused deposition modelling (FDM) with commodity plastics that lack cell-scale resolution and biological cues. The lack of biologically active materials, also called ‘bioinks,’ is a key issue that limits the ability to produce engineered tissues, tissue interfaces and functional organs. While advances are being made in the field of biomaterials, current technologies can be combined into hybrid systems that overcome the limitations of a single technique or material, as described in this article.

scholarly journals Development of Sensors by 3D Printing Technology-Fused Deposition Modelling

2019 ◽  
Vol 9 (1) ◽  
pp. 2182-2185 ◽  
Keyword(s):  
3D Printing ◽  
Case Studies ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Printing Technology ◽  
3D Printing Technology ◽  
Fused Deposition ◽  
Sensing Applications ◽  
Printed Sensors ◽  
Work Done

In present days the most commonly used methodology for making structures in three dimensional views is 3D printing technology. This technology is also referred as an additive manufacturing technology. This technology is being broadly used to improve functionality. Advances in utilization of this technology lead to sensing applications in monitoring health parameters. But, in general this type of multifunctional sensor involves with developments in better sensitivity and specificity. This paper mainly focusses a review about the work done on development of 3D printed sensors. Utilization of these techniques has increased in the domain of applications related to sensors as per the advances of being quickly fabricated and the high probability of processing different conductive materials. Representing the need and importance of 3D printing methodology in fabricating sensors, this article summarizes different 3D printing technologies and explains the utilization of fused deposition modelling method to fabricate sensing prototype. Advantages, disadvantages, materials that are being currently processed and case studies has been summarized in this paper. Chosen case studies review the importance of developing sensors with advanced performance.

Single and Multi-objective Optimization of Processing Parameters for Fused Deposition Modeling in 3D Printing Technology

2020 ◽  
Vol 17 (1) ◽  
pp. 7542-7551 ◽  
Author(s):  
V. H. Nguyen ◽  
T. N. Huynh ◽  
T. P. Nguyen ◽  
T. T. Tran
Keyword(s):  
Genetic Algorithm ◽  
3D Printing ◽  
Case Studies ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Processing Parameters ◽  
Fused Deposition Modelling ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Fused Deposition

This paper presents practice and application of Design of Experiment techniques and Genetic Algorithm in single and multi-objective optimization with low cost, robustness, and high effectiveness through 3D printing case studies. 3D printing brings many benefits for engineering design, product development, and production process. However, it faces many challenges related to parameters control. The wrong parameter setup can result in excessive time, high production cost, waste material, and low-quality printing. This study is conducted to optimize the parameter sets for 3D Fused Deposition Modelling (FDM) products. The parameter sets, i.e., layer height, infill percentage, printing temperature, printing speed with different levels are experimented and analyzed to build mathematic models. The objectives are to describe the relationship between the inputs (parameter values) and the outputs (printing quality in term of weight, printing time and tensile strength of products). Single-objective and multi-objective models according to user’s desire are constructed and studied to identify the optimal set, optimal trade-off set of parameters. Besides, an integrated method of response surface methodology and Genetic algorithm to deal with multi-objective optimization is discussed in the paper. 3D printer, testing machines, and quality tools are used for doing experiments, measurement and collecting data. Minitab and Matlab software aid for analysis and decision-making. Proposed solutions for handling multi-objective optimization through 3D Fused Deposition Modelling product printing case study are practical and can extend for other case studies.

Evaluation of a rapid prototyping application for stomas

2020 ◽  
Vol 26 (9) ◽  
pp. 1525-1533 ◽  
Author(s):  
Jose Manuel Sierra ◽  
Jose Ignacio Rodríguez ◽  
Marta María Villazon ◽  
Jose Luis Cortizo ◽  
Maria del Rocio Fernandez
Keyword(s):  
3D Printing ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Tests ◽  
Fused Deposition Modelling ◽  
Static Loads ◽  
Content Type ◽  
Fused Deposition ◽  
Collection Device ◽  
Low Costs ◽  
Butadiene Styrene

Purpose This paper aims to describe the development of an internal waste-collection device for patients who have undergone a colostomy or ileostomy. Its design is based on devices that have been produced by 3D printing with acrylonitrile butadiene styrene. The aim is to find an alternative to the external bags that these patients currently use and to evaluate the properties of the device produced by additive manufacturing. Design/methodology/approach Software for solid modelling has been used, and virtual models allow its visualization and animation, for evaluation, in a simple and fast way. Subsequently, functional prototypes have been developed by a multidisciplinary team, which includes surgeons and engineers, and have been tested to verify their mechanical properties and suitability for function. Findings The project has developed a functional design that has been patented and is in the clinical trials phase. This study demonstrates how 3D printing technologies are the perfect complement to accelerate the design process and build functional prototypes at low costs. The experimental tests regarding cytotoxicity, printing orientation, dynamic and static loads and temperature resistance have demonstrated the validity of the proposed device. Originality/value A device for internal pouch in colostomized patients has been designed, manufactured by fused deposition modelling and validated.

Sign in / Sign up

Export Citation Format

Share Document