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The goal of this work is to develop a framework for manufacturing nonuniform wall thickness replicas of abdominal aortic aneurysms (AAAs). The methodology was based on the use of computed tomography (CT) images for virtual modeling, additive manufacturing for the initial physical replica, and a vacuum casting process and range of polyurethane resins for the final rubberlike phantom. The average wall thickness of the resulting AAA phantom was compared with the average thickness of the corresponding patient-specific virtual model, obtaining an average dimensional mismatch of 180 μm (11.14%). The material characterization of the artery was determined from uniaxial tensile tests as various combinations of polyurethane resins were chosen due to their similarity with ex vivo AAA mechanical behavior in the physiological stress configuration. The proposed methodology yields AAA phantoms with nonuniform wall thickness using a fast and low-cost process. These replicas may be used in benchtop experiments to validate deformations obtained with numerical simulations using finite element analysis, or to validate optical methods developed to image ex vivo arterial deformations during pressure-inflation testing.

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An abdominal aortic aneurysm (AAA) is a permanent focal dilatation of the abdominal aorta of at least 1.5 times its normal diameter. Although the criterion of maximum diameter is still used in clinical practice to decide on a timely intervention, numerical studies have demonstrated the importance of other geometric factors. However, the major drawback of numerical studies is that they must be validated experimentally before clinical implementation. This work presents a new methodology to verify wall stress predicted from the numerical studies against the experimental testing. To this end, four AAA phantoms were manufactured using vacuum casting. The geometry of each phantom was subject to microcomputed tomography (μCT) scanning at zero and three other intraluminal pressures: 80, 100, and 120 mm Hg. A zero-pressure geometry algorithm was used to calculate the wall stress in the phantom, while the numerical wall stress was calculated with a finite-element analysis (FEA) solver based on the actual zero-pressure geometry subjected to 80, 100, and 120 mm Hg intraluminal pressure loading. Results demonstrate the moderate accuracy of this methodology with small relative differences in the average wall stress (1.14%). Additionally, the contribution of geometric factors to the wall stress distribution was statistically analyzed for the four phantoms. The results showed a significant correlation between wall thickness and mean curvature (MC) with wall stress.

Lattice structures produced by additive manufacturing have been increasingly studied in recent years due to their potential to tailor prescribed mechanical properties. Their mechanical performances are influenced by several factors such as unit cell topology, parent material and relative density. In this study, static and dynamic behaviors of Ti6Al4V lattice structures were analyzed focusing on the criteria used to define the failure of lattices. A modified face-centered cubic (FCCm) lattice structure was designed to avoid the manufacturing problems that arise in the production of horizontal struts by laser powder bed fusion. The Gibson–Ashby curves of the FCCm lattice were obtained and it was found that relative density not only affects stiffness and strength of the structures, but also has important implications on the assumption of macroscopic yield criterion. Regarding fatigue properties, a stiffness based criterion was analyzed to improve the assessment of lattice structure failure in load bearing applications, and the influence of relative density on the stiffness evolution was studied. Apart from common normalization of S–N curves, a more accurate fatigue failure surface was developed, which is also compatible with stiffness based failure criteria. Finally, the effect of hot isostatic pressing in FCCm structures was also studied.

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