Citation: PATERSON, A. ... et al., 2015 Comparison of Additive Manufacturing Systems for the Design and Fabrication of Customised Wrist SplintsPurpose -The purpose of this paper is to compare four different additive manufacturing (AM) processes in order to assess their suitability in the context of upper extremity splinting. Design/methodology/approach -This paper describes the design characteristics and subsequent fabrication of six different wrist splints using four different AM processes: Laser Sintering (LS), Fused Deposition Modelling (FDM), Stereolithography (SLA) and PolyJet material jetting via Objet Connex. The suitability of each process was then compared against competing designs and processes from traditional splinting. The splints were created using a digital design workflow that combined recognised clinical best practice with design for AM principles. Findings -Research concluded that, based on currently available technology, FDM was considered the least suitable AM process for upper extremity splinting. LS, SLA and material jetting show promise for future applications but further research and development into AM processes, materials and splint design optimisation are required if the full potential is to be realised. Originality/value -Unlike previous work that has applied AM processes to replicating traditional splint designs, the splints described are based on a digital design for AM workflow, incorporating novel features and physical properties not previously possible in clinical splinting. The benefits of AM for customised splint fabrication have been summarised. A range of AM processes have also been evaluated for splinting, exposing the limitations of existing technology, demonstrating novel and advantageous design features and opportunities for future research.
A series of nanocrystalline copper metallised and non-metallised Laser Sintered (LS) Nylon (PA2200) samples using the EOS P100 Formiga system, were stab tested to current Home Office Scientific Development Branch (HOSDB) Knife Resistance (KR) 2007 standards, to ascertain their stab resistant characteristics. The research demonstrated that while a sample thickness of 8mm virgin PA2200 was required for a successful stab test, this figure was significantly reduced to 5.6mm using a 50:50 mix of virgin and recycled PA2200. A further significant reduction in sample thickness to 4.5mm was also recorded for samples manufactured from virgin PA2200, metallised in a 150μm layer of nanocrystalline copper.The results of the stab testing series were then utilised to develop a non-metallised, scale Additive Manufactured (AM) textile manufactured from a 50:50 recycled and virgin PA2200 mix. Results indicated a successful AM textile-like design, with little or no penetration during stab testing at the HOSDB KR1 standard.
With additive manufacturing increasingly being embraced in the area of sports technology, focus has shifted toward cellular structures for impact protection. Periodic lattice structures can be tailored for a specific response by modifying the geometry of individual cells, with the structure capable of being modified to conform around a given body. However, the effect of modifying specific design characteristics within a lattice and the interrelationships between them are not well understood. This study examines five geometric design variables: cell width, strut cross-sectional area (CSA), strut shape, cell orientation, and joint filleting, and their effect on the compressive behavior of a lattice structure. Truncated octahedron lattices were manufactured using nylon through the process of material extrusion and tested under compression at a constant strain rate of 1.0 s-1. Design of experiments was utilized to analyze the results by implementing a 2 (5-1) factorial design. Results indicated that the strut CSA, cell width, and interaction between the two design characteristics had the largest effects on the plateau stress of the lattice and its energy capacity.
The design and assessment of bio-inspired Additive Manufactured stab resistant armour The performance of modern fibre-based or Polycarbonate armour has significantly progressed since their introduction, providing protection against a range of low and high velocity threats. While this is so, users of such armour frequently report of issues relating to their operational suitability resulting in impaired performance and physiological effects. Recently researchers have focussed on how naturally occurring protective mechanisms could be utilised to enhance the protective and operational performance of wearers of engineered body armour. The research presented within this paper therefore utilises a series of key design characteristics exhibited within naturally occurring elasmoid scale armour, coupled with established Laser Sintering manufacturing parameters, for the realisation and assessment of a scale-based stab resistant armoured structure to internationally recognised test standards.
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