OPTIMIZATION OF RAPID PROTOTYPING TECHNOLOGY

FOR ADVANCED MEDICAL APPLICATIONS

M.Sljivic, Mechanical Faculty,University of Banja Luka
M. Stanojevic, Mechanical Faculty,University of Banja Luka
N. Grujovic, Mechanical Faculty, University of Kragujevac
R.Radonjic, Mechanical Faculty, University of Banja Luka

2. PROCESS CHAIN OF RAPID 3. ANALYSIS OF RP PROCESS CHAIN 4. THE RESULTS OF CURRENT RESEARCH
1. INTRODUCTION
PROTOTYPING RELATING TO THE ERROR GENERATION
The major problems in preprocessing phase are, as follows:
1. fusion of separate body tissues in contact, what causes the overlaping of extracted edges,
MAJOR ASPECTS OF RAPID PROTOTYPING 2. roughness of extruded surfaces, which can be smoothed during tesselation,
CT, MRI - SCANNING 3. proper selection of parameters for tesselation.

PRE-PROCESSING PHASE -REVERSE ENGINEERING

I. APPLICATIONS II. METHOD CT - data (DICOM files *.dcm) Table 1. Performance comparison of RP systems
(Series of slices as raster images)
1. Design Single Laser Accuracy Roughness Part cost
Beam EDGE EXTRACTION and Methods
(μm) (μm) ($)
2. Engineering and Analysis 1. Photo Double Laser VECTORIZATION SLA 500 100-120 8 300
Curing Beams
3. Tooling and Manufacturing SLS 200 125-150 12 300
Masked Lamp Series of 2D curves along
bone edges FDM 150 28 250
Figure 4. Top view of image
Figure 3. Classical CT data in DICOM LOM 200 30 200
Biomedical, Consumer, 2. Cutting and Glueing/Joining processing and edge detection
format 3D print 400-500 16 50
Electrical and Electronics, 2,5D EQUIDISTANT
3. Melting and Solidifying/ DISTRIBUTION OF 2D CONTOURS Table 2. Computation results of sample cylinder
Automotive, Aerospace
Fusing triangulation (pre-assumption: maximum of cordial error
Products, etc.
Series 2,5D evenly is 0,1 mm, according to the allowed roughness error)
4. Joining/Binding
distributed contours
Length Number of triangles Size of stl files
III. INPUT IV. MATERIAL 3D MODELINIG BY EXTRUDING 50 404 16 KB
TOOLS 20 820 41 KB
1. Computer model – CAD 1. Laminates, Pellets, Wire 10 1780 87 KB
model, Surface or Solid 3D parameter-defined 6 2804 137 KB
model of bones
2. Powder 3 10972 536 KB
2. Physical Object – data
acquisition as Reverse
SEGMENTATION OF JOINT/ 1 189980 9277 KB
3. Liquid OVERLAPPED COMPONENTS AND Figure 5. Isometric view of image
Engineering by Point Data 0,5 505588 24687 KB
from Digitizer (CMM, laser SMOOTHING OF SURFACES processing and edge detection Figure 6. Isometric view of image processing and
digitizer, etc.) edge detection (before polishing/smothing)
*.stl i *.sla files *.igs , *.stp &
Paper, Resins, Nylon, ABS, *.CATPart files
Meshing – STL files
Wax, Metals, Ceramics, etc.
CHECKING & SLICING OF
PROCESSING

Slicing/Layer Information – SLI

files SURFACE MODEL

As it was mentioned, medical applications have some specific aspects to be

PROCESSING OF RAPID
considered. For medical applications with more cavities, it is recommendable PROTOTYPING MODEL
to use the RP methods without support structures like 3D Printing and SLS,
APPLICATIONS POSTPROCESSING

comparing with SLA and some MultiJet methods. The problem is, very Figure 7. Tessellation and smoothing of Figure 8. Tessellation parameters
REMOVING OF EXCEEDED body’s surfaces
difficult postprocessing of internal surfaces of models. For example, 3D
MATERIAL AND SURFACE
printing has not such kind of problem, because it uses the powder as material, POLISHING
which is cured by liquid binding material. So the rest of surrounding powder
is very easy to move it by special cleaning device.
STRENGTHENING OF SURFACE
AND/OR PAINTING
MEDICAL

RP MODEL Figure 10. Meshing for cordial error 0,1mm and length
Figure 11. Meshing for cordial error 0,1mm and
- Implantology length 3mm – for the simple body structures
1mm –for the finest body structures
- Tools for Computer Aided Surgery

5. CONCLUSION AND FOLLOWING RESEARCH

By this research, it is succeded to apply the Reverse Engineering and Rapid Prototyping on the practical
purposes for Computer Aided Surgery in orthopaedic applications in Banja Luka.
Practical using in medical apllications of this research, provides some recommendations for preprocessing
Figure 14. Meshing with adaptive structure –
phase to prepare the models with optmized parameters. Figure 13. Meshing without adaptation of
lower number of triangles and kept cordial
In the next stage of research, there is a focus on processing and especially post processing phase with the aim structure – larger number of triangles
error
to develop new methods for strengthening of RP models, by controlled coating of outer surfaces.
In the next figure, it is concerete presentations of computer aided surgery and measuring some important
parameters for implantation.

Figure 15. Measuring of important parameters for surgery preparation and implantation
Figure 16. RP model of femur