Cranial Reconstruction Using Double Side Incremental Forming

Lü, Bin; Xu, D.; Liu, Run Zhe; Ou, Hengan; Long, Hui; Chen, Jun

doi:10.4028/www.scientific.net/kem.639.535

Cited by 28 publications

(11 citation statements)

References 29 publications

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“…Generally, with this manufacture, the prosthesis has a greater area and, so, a larger perimeter in respect to the defect [11], but no information regarding the anchoring system is available, in terms of overlap length and diameter of screw shank.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, titanium custom-made craniofacial prostheses can be made using the Incremental Sheet Forming (ISF), a manufacturing process with significant vantages [8][9][10][11]. Generally, with this manufacture, the prosthesis has a greater area and, so, a larger perimeter in respect to the defect [11], but no information regarding the anchoring system is available, in terms of overlap length and diameter of screw shank.…”

Section: Introductionmentioning

confidence: 99%

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Support Tool for Anchoring System Optimization of Titanium Craniofacial Prostheses

et al. 2016

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Abstract. Titanium prostheses are artificial components used during cranioplasty, which can be made with the Incremental Sheet Forming (ISF). To repair the craniofacial defects, the implant must be fixed to the skull, so an adequate anchoring system is necessary. Because there are no specific guidelines regarding this system, the aim of this study was to present a methodology for the identification of the optimal screw shank diameter and the overlap length, considering different damage areas and accidental external loads. In this method, a numerical model for structural analysis, a statistical approach and a metamodeling technique were coupled. The results demonstrate that this methodology can be used as a decision support tool in the titanium prostheses design, ensuring the best anchorage.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Support Tool for Anchoring System Optimization of Titanium Craniofacial Prostheses

et al. 2016

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“…Despite a number of efforts to make medical implant shapes using ISF [2][3][4][5][6][7][8], making these parts with high accuracy has been a problem. Even though Behera et al [2] tried forming implant shapes with high forming angles with improved accuracy, the part made of titanium grade II failed.…”

Section: Introductionmentioning

confidence: 99%

“…Variants include the use of a counter-support tool and use of dies, either full or partial. A number of efforts have been made to manufacture implants and supports for different parts of the human body using ISF such as the skull [2][3][4][5], knee [6], face [7], and ankle support [8] using ISF.…”

Section: Introductionmentioning

confidence: 99%

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Behera

Lü

2015

Int J Adv Manuf Technol

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Single point incremental forming (SPIF) is a relatively new manufacturing process that has been recently used to form medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. Prior work on accuracy characterization has shown that feature behavior is important in predicting accuracy. In this study, a set of basic geometric shapes consisting of ruled and freeform features were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions using multivariate adaptive regression splines (MARS) are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, distance to feature borders, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case where the curvatures in the part lie between that of ruled features and freeform features. It is shown that a mixed-MARS response surface model using a weighted average of the ruled and freeform surface models can be used for such a case to improve the mean prediction accuracy within ±0.5 mm. The predicted deviations show a reasonable match with the actual formed shape for the implant case and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants.

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“…To enable this, one relatively new manufacturing technique that has come forth is Incremental Sheet Forming (ISF). A number of efforts have been made to manufacture implants and supports for different parts of the human body such as the skull [2][3][4][5], knee [6], face [7], ankle support [8].…”

Section: Introductionmentioning

confidence: 99%

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts

Behera

Lü

2015

MATEC Web of Conferences

Self Cite

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Abstract. Single Point Incremental Forming (SPIF) is a relatively new process that has been recently used to manufacture medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. In this study, a set of basic geometric shapes were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case. The predicted deviations show a reasonable match with the actual formed shape and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants.

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Cranial Reconstruction Using Double Side Incremental Forming

Abstract: Abstract. Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. Comparing to conventional sheet forming processes,

Cited by 28 publications

References 29 publications

Support Tool for Anchoring System Optimization of Titanium Craniofacial Prostheses

Support Tool for Anchoring System Optimization of Titanium Craniofacial Prostheses

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts

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