Additive manufacturing of individual bone implants made of bioresorbable calcium phosphate cement using the example of large skull defects
Stefan Holtzhausen, Philipp Sembdner, Martin Pendzik, Holger Wilhelm Rudolf Schmidt, Kristin Paetzold-Byhain
Technische Universität Dresden, Germany
In the field of individualized medical implants for bone replacement, additive manufacturing offers far-reaching advantages for bridging bone defects and supporting the production of natural form and function. The article uses the example of a large, customized cranial implant to show the challenges of manufacturing with osteoinductive bone cements. The process is shown, starting with planning and design, through to functional integration using adapted manufacturing strategies to create defined porosity.
Stress concentrations and design for additive manufacturing: a design artefact approach to investigation
Didunoluwa Obilanade1, Owen Rahmat Peckham2, Adam McClenaghan2, James Gopsill2, Peter Törlind1
1Luleå University of Technology, Sweden; 2University of Bristol, United Kingdom
The accelerated rate of product development and design complexities offered by Additive Manufacturing (AM) has allowed for innovation in the space industry. However, the surface roughness of parts poses a challenge, as it impacts performance and is tied to design choices. Design tools for traditional manufacturing methods fall short in AM contexts, prompting the need for alternative design processes. This work proposes an experimental approach to design for AM investigation using design artefacts to explore a process-structure-property-performance relationship.
Topology optimisation of multiple robot links considering screw connections
Tobias Wanninger, Jintin Frank, Markus Zimmermann
Technical University of Munich, TUM School of Engineering and Design, Department of Mechanical Engineering, Laboratory for Product Development and Lightweight Design, Germany
This paper presents a method for the lightweight design of robotic links subject to dynamic loads and requirements on the overall system stiffness. It includes (1) a decomposition scheme to enable separate component optimization and (2) an approach based on topology optimization for optimal load path design of screw connections. The approach reduces computing cost and mass of designs with screw connections.
Additive manufacturing in fluid power with novel application to hydraulic pump design
Anton Wiberg, Liselott Ericson, Johan A. Persson, Johan Ölvander
Linköping University, Sweden
Additive Manufacturing (AM) enhances component functionality in engineering. This study explores AM benefits for hydraulic pumps, by reviewing literature on fluid power and existing AM successes in pumps, pipes, and manifolds. While hydraulic pump research is scarce, the study redesigns a pump, mirroring successes in other hydraulic areas. Predicted outcomes include a 45-85% pressure drop reduction, 35% weight reduction, and fewer parts compared to traditional pumps, achieved with minor design changes. Larger-scale redesigns promise even greater improvements.
Design challenges in leveraging binder jetting technology to innovate the medical instrument field
Lorenzo Cocchi, Marco Mariani, Serena Graziosi, Roberto Viganò, Nora Lecis
Politecnico di Milano, Italy
Despite its significant advantages in terms of design freedom and the wide range of processable materials, the Binder Jetting technology has not yet received substantial attention in the healthcare field, especially concerning the fabrication of metal components. Hence, the paper investigates how this technology could be exploited to innovate the medical instrument field. Based on selected case studies, some preliminary design indications are derived on how to properly consider the various phases (i.e., printing, depowdering, and sintering) and related challenges of the Binder Jetting process.
Improving sustainability of additive manufacturing processes based on digital twins – a case study
Jessica Kos1, Philipp Schröder1, Jakob Trauer2, Felix Endress1, Markus Mörtl1, Markus Zimmermann1
1Technical University of Munich, TUM School of Engineering and Design, Laboratory for Product Development and Lightweight Design, Germany; 2em engineering methods AG, Germany
Additive manufacturing (AM) became a key technology in the development of innovative products. Advancements have been made to improve economic feasibility. However, ecological sustainability is still an open issue of AM. To improve sustainability, it is crucial to track, visualize, and evaluate emissions along the lifecycle. This paper presents a novel Digital Twin based approach enabling prediction of the product carbon footprint (PCF) and prescriptive measures to improve sustainability. By improving part and process design, a significant PCF reduction was achieved.
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