A method to design and manufacture low-cost patient-specific templates for spinal surgery: evaluation of multiple additive manufacturing methods

2018 ◽  
Vol 2 (4) ◽  
pp. 169-177
Author(s):  
David R Rutkowski ◽  
Derrick Sun ◽  
Paul A Anderson ◽  
Alejandro Roldán-Alzate
Keyword(s):  
Additive Manufacturing ◽  
Spinal Surgery ◽  
Low Cost ◽  
Patient Specific ◽  
Manufacturing Methods ◽  
Design And Manufacture

scholarly journals 3D Digitization and Additive Manufacturing Technologies in Medicine

2018 ◽  
Vol 26 (42) ◽  
pp. 165-170
Author(s):  
Ivan Molnár ◽  
Ladislav Morovič
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Processes ◽  
Design And Manufacturing ◽  
Medical Aids ◽  
Manufacturing Methods ◽  
Manufacturing Technologies ◽  
Design And Manufacture ◽  
3D Digitization ◽  
The Given

Abstract The paper discusses the use of 3D digitization and additive manufacturing technologies in the field of medicine. In addition, applications of the use of 3D digitization and additive manufacturing methods are described, focusing on the design and manufacture of individual medical aids. Subsequently, the process of designing and manufacturing of orthopedic aids using these technologies is described and the advantages of introducing the given technologies into the design and manufacturing processes in the medicine sector are presented.

scholarly journals A Comprehensive 3D-Molded Bone Flap Protocol for Patient-Specific Cranioplasty

2021 ◽  
Author(s):  
Raphael Bertani ◽  
Caio Moreno Perret Novo ◽  
Pedro Henrique Freitas ◽  
Amanda Amorin Nunes ◽  
Thiago Nunes Palhares ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Selective Laser Sintering ◽  
Operating Time ◽  
Ct Scanning ◽  
Patient Specific ◽  
Manufacturing Cost ◽  
Post Processing ◽  
Cross Sectional ◽  
Cranial Defect

Abstract We present a detailed step-by-step approach for the low-cost production and surgical implantation of cranial prostheses, aimed at restoring aesthetics, cerebral protection, and facilitating neurological rehabilitation. This protocol uses combined scan computed tomography (CT) cross-sectional images, in DICOM format, along with a 3D printing (additive manufacturing) setup. The in-house developed software InVesalius®️ is an open-source tool for medical imaging manipulation. The protocol describes image acquisition (CT scanning) procedures, and image post-processing procedures such as image segmentation, surface/volume rendering, mesh generation of a 3D digital model of the cranial defect and the desired prostheses, and their preparation for use in 3D printers. Furthermore, the protocol describes a detailed powder bed fusion additive manufacturing process, known as Selective Laser Sintering (SLS), using Polyamide (PA12) as feedstock to produce a 3-piece customized printed set per patient. Each set consists of a “cranial defect printout” and a “testing prosthesis” to assemble parts for precision testing, and a cranial “prostheses mold” in 2 parts to allow for the intraoperative modeling of the final implant cast using the medical grade Poly(methyl methacrylate) (PMMA) in a time span of a few min. The entire 3D processing time, including modelling, design, production, post-processing and qualification, takes approximately 42 h. Modeling the PMMA flap with a critical thickness of 4 mm by means of Finite Element Method (FEM) assures mechanical and impact properties to be slightly weaker than the bone tissue around it, a safety design to prevent fracturing the skull after a possible subsequent episode of head injury. On a parallel track, the Protocol seeks to provide guidance in the context of equipment, manufacturing cost and troubleshooting. Customized 3D PMMA prostheses offers a reduced operating time, good biocompatibility, and great functional and aesthetic outcomes. Additionally, it offers greater than 15-fold cost advantage over the usage of other materials, including metallic parts produced by additive manufacturing.

scholarly journals A Systematic Review on 3D-Printed Imaging and Dosimetry Phantoms in Radiation Therapy

2019 ◽  
Vol 18 ◽  
pp. 153303381987020 ◽  
Author(s):  
Rance Tino ◽  
Adam Yeo ◽  
Martin Leary ◽  
Milan Brandt ◽  
Tomas Kron
Keyword(s):  
Systematic Review ◽  
Quality Assurance ◽  
Additive Manufacturing ◽  
Image Quality Assessment ◽  
Low Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Limiting Factors ◽  
Patient Specific ◽  
Wide Range ◽  
Assurance Process

Introduction: Additive manufacturing or 3-dimensional printing has become a widespread technology with many applications in medicine. We have conducted a systematic review of its application in radiation oncology with a particular emphasis on the creation of phantoms for image quality assessment and radiation dosimetry. Traditionally used phantoms for quality assurance in radiotherapy are often constraint by simplified geometry and homogenous nature to perform imaging analysis or pretreatment dosimetric verification. Such phantoms are limited due to their ability in only representing the average human body, not only in proportion and radiation properties but also do not accommodate pathological features. These limiting factors restrict the patient-specific quality assurance process to verify image-guided positioning accuracy and/or dose accuracy in “water-like” condition. Methods and Results: English speaking manuscripts published since 2008 were searched in 5 databases (Google Scholar, Scopus, PubMed, IEEE Xplore, and Web of Science). A significant increase in publications over the 10 years was observed with imaging and dosimetry phantoms about the same total number (52 vs 50). Key features of additive manufacturing are the customization with creation of realistic pathology as well as the ability to vary density and as such contrast. Commonly used printing materials, such as polylactic acid, acrylonitrile butadiene styrene, high-impact polystyrene and many more, are utilized to achieve a wide range of achievable X-ray attenuation values from −1000 HU to 500 HU and higher. Not surprisingly, multimaterial printing using the polymer jetting technology is emerging as an important printing process with its ability to create heterogeneous phantoms for dosimetry in radiotherapy. Conclusion: Given the flexibility and increasing availability and low cost of additive manufacturing, it can be expected that its applications for radiation medicine will continue to increase.

scholarly journals Application of 3D Printing Technology in Orthopedic Medical Implant -Spinal surgery as an example

2019 ◽  
Vol 5 (2) ◽  
pp. 3
Author(s):  
Rong Feng Zhang ◽  
Peng Yun Wang ◽  
Ming Yang ◽  
Xuebo Dong ◽  
Xue Liu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Spinal Surgery ◽  
Surgical Planning ◽  
Operating Time ◽  
Manufacturing Technology ◽  
Patient Specific ◽  
Additive Manufacturing Technology ◽  
Patient Specific Implants ◽  
Surgical Guides ◽  
Communication Aid

Additive manufacturing has been used in complex spinal surgical planning since the 1990s and is now increasingly utilized to produce surgical guides, templates, and more recently customized implants. Surgeons report beneficial impacts using additively manufactured biomodels as pre-operative planning aids as it generally provides a better representation of the patient’s anatomy than on-screen viewing of computed tomography (CT) or magnetic resonance imaging (MRI). Furthermore, it has proven to be very beneficial in surgical training and in explaining complex deformity and surgical plans to patients/ parents. This paper reviews the historical perspective, current use, and future directions in using additive manufacturing in complex spinal surgery cases. This review reflects the authors’ opinion of where the field is moving in light of the current literature. Despite the reported benefits of additive manufacturing for surgical planning in recent years, it remains a high niche market. This review raises the question as to why the use of this technology has not progressed more rapidly despite the reported advantages – decreased operating time, decreased radiation exposure to patients intraoperatively, improved overall surgical outcomes, pre-operative implant selection, as well as being an excellent communication aid for all medical and surgical team members. Increasingly, the greatest benefits of additive manufacturing technology in spinal surgery are customdesigned drill guides, templates for pedicle screw placement, and customized patient-specific implants. In view of these applications, additive manufacturing technology could potentially revolutionize health care in the near future.

Experimental study on cushioning behaviors of foam with different skin-liked covers

2021 ◽  
Vol 263 (3) ◽  
pp. 3633-3642
Author(s):  
Heye Xiao ◽  
Focai Yuan ◽  
Xudong Zhang ◽  
Chizhen Xu ◽  
Jie Zhou
Keyword(s):  
Experimental Study ◽  
Additive Manufacturing ◽  
Structural Design ◽  
Static Loading ◽  
Periodic Structures ◽  
Low Cost ◽  
Acceleration Response ◽  
Manufacturing Methods

Periodic structures were used in foams to improve their cushioning ability in previous studieswhich are usually constructed by additive manufacturing methods with high cost. To improve cushioning property of the foam materials at a low cost, foams with skin covers are proposed in this paper to provide a new idea for a structural design that is inspired by the composition of animal skins. The foam without covers and covered with three different skin types, including square shape, circle shape, and Pearlfish skin, are investigated in this study. The stiffness and acceleration responses of these structures are measured by static loading and dropping test respectively, which are used to evaluate their static and dynamic cushion properties. Based on the tested results, it demonstrated that the cover skins could improve the stiffness of the foam materials and decrease acceleration response of mass fixing on them in dropping test at 0.4 m and 0.5 m. The enhancement for cushion ability of the proposed structure in this paper is proved experimentally.

scholarly journals Size Effects in Finite Element Modelling of 3D Printed Bone Scaffolds Using Hydroxyapatite PEOT/PBT Composites

Mathematics ◽  
2021 ◽  
Vol 9 (15) ◽  
pp. 1746
Author(s):  
Iñigo Calderon-Uriszar-Aldaca ◽  
Sergio Perez ◽  
Ravi Sinha ◽  
Maria Camara-Torres ◽  
Sara Villanueva ◽  
...  
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Tissue Regeneration ◽  
Finite Element Modelling ◽  
Bulk Material ◽  
Bone Tissue Regeneration ◽  
Patient Specific ◽  
Design Factor ◽  
Element Modelling ◽  
Uncertainty Sources

Additive manufacturing (AM) of scaffolds enables the fabrication of customized patient-specific implants for tissue regeneration. Scaffold customization does not involve only the macroscale shape of the final implant, but also their microscopic pore geometry and material properties, which are dependent on optimizable topology. A good match between the experimental data of AM scaffolds and the models is obtained when there is just a few millimetres at least in one direction. Here, we describe a methodology to perform finite element modelling on AM scaffolds for bone tissue regeneration with clinically relevant dimensions (i.e., volume > 1 cm3). The simulation used an equivalent cubic eight node finite elements mesh, and the materials properties were derived both empirically and numerically, from bulk material direct testing and simulated tests on scaffolds. The experimental validation was performed using poly(ethylene oxide terephthalate)-poly(butylene terephthalate) (PEOT/PBT) copolymers and 45 wt% nano hydroxyapatite fillers composites. By applying this methodology on three separate scaffold architectures with volumes larger than 1 cm3, the simulations overestimated the scaffold performance, resulting in 150–290% stiffer than average values obtained in the validation tests. The results mismatch highlighted the relevance of the lack of printing accuracy that is characteristic of the additive manufacturing process. Accordingly, a sensitivity analysis was performed on nine detected uncertainty sources, studying their influence. After the definition of acceptable execution tolerances and reliability levels, a design factor was defined to calibrate the methodology under expectable and conservative scenarios.

Influence of Specimen Layout on 17-4PH (AISI 630) Alloys Fabricated by Low-Cost Additive Manufacturing

2021 ◽  
Author(s):  
Chanun Suwanpreecha ◽  
Phanuphak Seensattayawong ◽  
Vorawat Vadhanakovint ◽  
Anchalee Manonukul
Keyword(s):  
Additive Manufacturing ◽  
Low Cost

Printing of Low Cost Sensors by Additive Manufacturing

2021 ◽  
Author(s):  
Salman Ahmad ◽  
Muhammad Shakeel ◽  
Nadeem Iqbal ◽  
Mohsin Amin ◽  
Khalid Rahman
Keyword(s):  
Additive Manufacturing ◽  
Low Cost

scholarly journals Rapid fabrication of MOF-based mixed matrix membranes through digital light processing

2021 ◽  
Author(s):  
Alexey Pustovarenko ◽  
Beatriz Seoane ◽  
Edy Abou-Hamad ◽  
Helen E King ◽  
Bert Weckhuysen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Processing Speed ◽  
Mixed Matrix Membranes ◽  
Scientific Interest ◽  
Mixed Matrix ◽  
Digital Light Processing ◽  
Additive Manufacturing Technology ◽  
Rapid Fabrication ◽  
Manufacturing Methods

3D printing, also known as additive manufacturing technology, has greatly expanded across multiple sectors of technology replacing classical manufacturing methods by combining processing speed and high precision. The scientific interest...

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