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Fabrication of Patient Specific Knee Implant by Fused Deposition Modeling
Available online at www.sciencedirect.com
ScienceDirect Materials Today: Proceedings 18 (2019) 3638–3642
www.materialstoday.com/proceedings
ICMPC-2019
Fabrication of Patient Specific Knee Implant by Fused Deposition Modeling Rajesh Boorla a, Prabeena T b
b
a Assistant Professor, Department of Mechanical Engineering, S R Engineering College, Warangal, Telangana, India. Assistant Professor, Department of Mechanical Engineering, Christu Jyothi Institute of Technology & Science, Jangaon,Telangana, India.
Abstract The aim of this research work is to Fabricate Patient Specific knee implant which is a surgical method of replacing the load bearing surfaces present in the knee joint so as to fix the pain bearing locals and inability zones of the joint. In this research, a proposed three-dimensional model of knee implant is developed from stl file which was obtained from sunshine hospital, secunderabad by using Fused Deposition modeling additive manufacturing process. Fabricated specimen is developed in software’s like meshlab, NetFabb and CATIA. After getting 3D model, it is then given to FDM machine for building. The knee implant printing time and material consumed is determined. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords: knee implant; makerbot software; tibia; femur; Polyethylene plate.
1.Introduction Knee replacement is also termed as knee anthroplasty. The purpose of knee replacement surgery is to cut away the harmed bone of the knee joint and supplant it with smooth, artificial implants know as prostheses [1]. This keeps the bones from rubbing together and gives a smooth knee joint. Artificial joints should satisfy certain design requirements; they should be ergonomically as well as biocompatible [2]. Following are the three components of a knee. Femoral component: It is made of metal piece which is attached to end of the femur. It has a groove that enables the patellar part to slide here and there easily as the knee twists and rectifies. Tibial segment: this level, two-piece metal and polyethylene (plastic) part is appended to the tibia. The metal part sits over the tibia and has a stem that is embedded into the tibia for stability. The plastic part, or Tibial spacer, goes about as a pad between the metal Tibial segment and the metal femoral segment. Corresponding author. E-mail address: [email protected] 2214-7853© 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
3639
Meniscus: the term meniscus is used to refer to the cartilage of the knee, either to the laterial or medical meniscus. Both are cartilaginous tissues that provide structural integrity to the knee when it experiences strain and torsion. 1.1 Additive Manufacturing Additive Manufacturing (AM) is an appropriate name to describe the technologies that build 3D objects by adding layer-upon-layer of material, regardless of whether the material is plastic, metal, concrete or one day human tissue [3]. Basic to AM innovations is the utilization of a computer, 3D modeling software (Computer Aided Design or CAD), machine equipment and layering material [4]. When a CAD drawing is created, the AM hardware peruses in information from the CAD document and lays downs or includes progressive layers of fluid, powder, sheet material or other, in a layer-upon-layer mold to manufacture a 3D object. 1.2 Fused Deposition Modelling (FDM): Additive manufacturing technology that builds parts layer by layer, by heating and extruding the thermoplastic filament. FDM is ideal for building durable components with complex geometries in nearly any shape and size [5-6]. FDM is only 3D printing process that uses materials like ABS, PC-ISO polycarbonate, and ULTEM 9085, which means FDM can create parts with outstanding thermal and chemical resistance, and excellent strength to weight ratios. 2. Methodology 2.1 Manufacturing of knee Implant: Once the stl file is obtained by 3D Scanning process, manufacturing of prototype knee implant parts is done on MAKERBOT REPLICATOR 2X machine using ABS material. 2.2 By MakerBot Replicator 2X: It is a 3D printing machine which produces parts by Fused Deposition Modeling (FDM) processes. The material used for printing knee Implant is ABS (Acylonitrile Butadiene Styrene) as shown in below Fig 1.
Figure 1: makerbot replicator 2x
The software used for printing plastic implant by MakerBot replicator 2 x machine is MakerBot desktop v3.9.1. The plastic knee implant parts are printed by MakerBot replicator 2X, located in Mahindra Ecole Centrale Engineering College, Hyderabad.
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R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
2.3 Knee femur: It is imported to MakerBot desktop v 3.9.1 software. Once the stl file is imported, the position, rotation and dimension of the implant to be printed in MakerBot are to be cross-checked as shown in below Fig 2.
Figure 2: Importing knee femur STL File to MakerBot Desktop software, Dimensions X = 63.53mm, Y = 59.44mm, Z = 51.33mm
If position, rotation and dimension are set, then in settings tab: 1. Quality of implant to be printed is chosen as standard. 2. Raft and support structure are chosen for printing of implant, since raft act as base for the implant part which has to be printed and support structures act as medium for printing the corner edges. 3. Since only a single part is printed at a time, right extruder is chosen. 4. For printing the implant part, the base temperature is maintained at 115 °C, and right extruder temperature is maintained at 230°C as shown in below Fig 3.
Figure 3: Setting the quality of print and choosing raft and supports.
R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
3641
5. Once the gap is verified, 3D printing process is started, where the base plate (i.e. platform) and extruder temperature are heated to 115°C and 220°C. 6. After all parameters are set in software; the file format is exported to X3G format, which is readable by MakerBot replicator 2X machine. 7. The X3G file is copied to memory card, which is then placed in MakerBot machine for printing process. 8. In the machine, 0.1 to 0.5 mm thickness object (e.g. Visiting Card) is allowed to pass between the gap of the extruder and base plate (or platform) to allow smooth printing without any errors. 9. After the required temperature of 115°C for platform and 220°C for right extruder is obtained, first the raft is printed according to the implant shape, above the raft, the required implant is printed using plastic ABS material. 10. The final 3D knee implant (ABS) printed as shown in below Fig 4 and Fig 5.
Figure 4: increasing of temperature of platform and right extruder
3. Results and Discussions
Figure 5: Printing of femur part.
3642
R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
3.1 Tibia part: The stl file of tibia part is imported to MakerBot software, to reduce the time, quantity of material used in printing, the solid part facing downwards is rotated upwards along X-Axis by 90°. Similar procedure (in software and in MakerBot machine) is followed as similar to the one used for printing the femur part as shown in below Fig 6 and Fig 7.
Fig 6: Printing of tibia part
Fig 7 femur part.
3.2 Polyethylene plate: The stl file of polyethylene is imported to MakerBot software to reduce the time, quantity of material used in printing, the solid part facing downwards is rotated upwards along X-Axis by 90°. Similar procedure (in software and in MakerBot machine) is followed as similar to the one used for printing the tibia part. 4. Conclusion Knee implant is designed by taking the dimensions from STL file in CATIA software. The printing time and material consumed for specificed and commercial knee implants are 25min, 9.24gms and 50min, 18gms. Finally the authors obtained the printing of tibia part and fabrication of patient specific knee implants is done using FDM machine. References [1] A. Stwora, G. Skrabalak “Influence of selected parameters of Selective Laser Sintering process on properties of sintered materials”, Journal of achievements in materials and manufacturing engineering. 61:2 (2013) 375-380. [2] Liciane Sabadin Bertol, Wilson Kindlein Júnior, Fabio Pinto da Silva, Claus Aumund-Kopp,“Medical design: Direct metal laser sintering of Ti–6Al–4V”,Journal of the Materials and design, DOI:10.1016. 31 (2010) 3982–3988. [3] Lombardi AV Jr1, Berend KR, Adams JB. Why knee replacements fail in 2013. 96 (2014). [4] William Morrison, MD , international journal of additive manufacturing technologies; July 23, (2018) 68-74. [5] C K Basavaraj1 and M Vishwas2, Studies on the effect of fused deposition modeling, “IOP Conference Series: Materials Science and Engineering,”149. [6] Shivraj Yeole, P.Chennakesava Sai. Fused deposition modelling insights.” International Conference on Advances in Design & Manufacturing (2014)”1345-1350.
ScienceDirect Materials Today: Proceedings 18 (2019) 3638–3642
www.materialstoday.com/proceedings
ICMPC-2019
Fabrication of Patient Specific Knee Implant by Fused Deposition Modeling Rajesh Boorla a, Prabeena T b
b
a Assistant Professor, Department of Mechanical Engineering, S R Engineering College, Warangal, Telangana, India. Assistant Professor, Department of Mechanical Engineering, Christu Jyothi Institute of Technology & Science, Jangaon,Telangana, India.
Abstract The aim of this research work is to Fabricate Patient Specific knee implant which is a surgical method of replacing the load bearing surfaces present in the knee joint so as to fix the pain bearing locals and inability zones of the joint. In this research, a proposed three-dimensional model of knee implant is developed from stl file which was obtained from sunshine hospital, secunderabad by using Fused Deposition modeling additive manufacturing process. Fabricated specimen is developed in software’s like meshlab, NetFabb and CATIA. After getting 3D model, it is then given to FDM machine for building. The knee implant printing time and material consumed is determined. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords: knee implant; makerbot software; tibia; femur; Polyethylene plate.
1.Introduction Knee replacement is also termed as knee anthroplasty. The purpose of knee replacement surgery is to cut away the harmed bone of the knee joint and supplant it with smooth, artificial implants know as prostheses [1]. This keeps the bones from rubbing together and gives a smooth knee joint. Artificial joints should satisfy certain design requirements; they should be ergonomically as well as biocompatible [2]. Following are the three components of a knee. Femoral component: It is made of metal piece which is attached to end of the femur. It has a groove that enables the patellar part to slide here and there easily as the knee twists and rectifies. Tibial segment: this level, two-piece metal and polyethylene (plastic) part is appended to the tibia. The metal part sits over the tibia and has a stem that is embedded into the tibia for stability. The plastic part, or Tibial spacer, goes about as a pad between the metal Tibial segment and the metal femoral segment. Corresponding author. E-mail address: [email protected] 2214-7853© 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
3639
Meniscus: the term meniscus is used to refer to the cartilage of the knee, either to the laterial or medical meniscus. Both are cartilaginous tissues that provide structural integrity to the knee when it experiences strain and torsion. 1.1 Additive Manufacturing Additive Manufacturing (AM) is an appropriate name to describe the technologies that build 3D objects by adding layer-upon-layer of material, regardless of whether the material is plastic, metal, concrete or one day human tissue [3]. Basic to AM innovations is the utilization of a computer, 3D modeling software (Computer Aided Design or CAD), machine equipment and layering material [4]. When a CAD drawing is created, the AM hardware peruses in information from the CAD document and lays downs or includes progressive layers of fluid, powder, sheet material or other, in a layer-upon-layer mold to manufacture a 3D object. 1.2 Fused Deposition Modelling (FDM): Additive manufacturing technology that builds parts layer by layer, by heating and extruding the thermoplastic filament. FDM is ideal for building durable components with complex geometries in nearly any shape and size [5-6]. FDM is only 3D printing process that uses materials like ABS, PC-ISO polycarbonate, and ULTEM 9085, which means FDM can create parts with outstanding thermal and chemical resistance, and excellent strength to weight ratios. 2. Methodology 2.1 Manufacturing of knee Implant: Once the stl file is obtained by 3D Scanning process, manufacturing of prototype knee implant parts is done on MAKERBOT REPLICATOR 2X machine using ABS material. 2.2 By MakerBot Replicator 2X: It is a 3D printing machine which produces parts by Fused Deposition Modeling (FDM) processes. The material used for printing knee Implant is ABS (Acylonitrile Butadiene Styrene) as shown in below Fig 1.
Figure 1: makerbot replicator 2x
The software used for printing plastic implant by MakerBot replicator 2 x machine is MakerBot desktop v3.9.1. The plastic knee implant parts are printed by MakerBot replicator 2X, located in Mahindra Ecole Centrale Engineering College, Hyderabad.
3640
R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
2.3 Knee femur: It is imported to MakerBot desktop v 3.9.1 software. Once the stl file is imported, the position, rotation and dimension of the implant to be printed in MakerBot are to be cross-checked as shown in below Fig 2.
Figure 2: Importing knee femur STL File to MakerBot Desktop software, Dimensions X = 63.53mm, Y = 59.44mm, Z = 51.33mm
If position, rotation and dimension are set, then in settings tab: 1. Quality of implant to be printed is chosen as standard. 2. Raft and support structure are chosen for printing of implant, since raft act as base for the implant part which has to be printed and support structures act as medium for printing the corner edges. 3. Since only a single part is printed at a time, right extruder is chosen. 4. For printing the implant part, the base temperature is maintained at 115 °C, and right extruder temperature is maintained at 230°C as shown in below Fig 3.
Figure 3: Setting the quality of print and choosing raft and supports.
R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
3641
5. Once the gap is verified, 3D printing process is started, where the base plate (i.e. platform) and extruder temperature are heated to 115°C and 220°C. 6. After all parameters are set in software; the file format is exported to X3G format, which is readable by MakerBot replicator 2X machine. 7. The X3G file is copied to memory card, which is then placed in MakerBot machine for printing process. 8. In the machine, 0.1 to 0.5 mm thickness object (e.g. Visiting Card) is allowed to pass between the gap of the extruder and base plate (or platform) to allow smooth printing without any errors. 9. After the required temperature of 115°C for platform and 220°C for right extruder is obtained, first the raft is printed according to the implant shape, above the raft, the required implant is printed using plastic ABS material. 10. The final 3D knee implant (ABS) printed as shown in below Fig 4 and Fig 5.
Figure 4: increasing of temperature of platform and right extruder
3. Results and Discussions
Figure 5: Printing of femur part.
3642
R. Boorla and Prabeena T./ Materials Today: Proceedings 18 (2019) 3638–3642
3.1 Tibia part: The stl file of tibia part is imported to MakerBot software, to reduce the time, quantity of material used in printing, the solid part facing downwards is rotated upwards along X-Axis by 90°. Similar procedure (in software and in MakerBot machine) is followed as similar to the one used for printing the femur part as shown in below Fig 6 and Fig 7.
Fig 6: Printing of tibia part
Fig 7 femur part.
3.2 Polyethylene plate: The stl file of polyethylene is imported to MakerBot software to reduce the time, quantity of material used in printing, the solid part facing downwards is rotated upwards along X-Axis by 90°. Similar procedure (in software and in MakerBot machine) is followed as similar to the one used for printing the tibia part. 4. Conclusion Knee implant is designed by taking the dimensions from STL file in CATIA software. The printing time and material consumed for specificed and commercial knee implants are 25min, 9.24gms and 50min, 18gms. Finally the authors obtained the printing of tibia part and fabrication of patient specific knee implants is done using FDM machine. References [1] A. Stwora, G. Skrabalak “Influence of selected parameters of Selective Laser Sintering process on properties of sintered materials”, Journal of achievements in materials and manufacturing engineering. 61:2 (2013) 375-380. [2] Liciane Sabadin Bertol, Wilson Kindlein Júnior, Fabio Pinto da Silva, Claus Aumund-Kopp,“Medical design: Direct metal laser sintering of Ti–6Al–4V”,Journal of the Materials and design, DOI:10.1016. 31 (2010) 3982–3988. [3] Lombardi AV Jr1, Berend KR, Adams JB. Why knee replacements fail in 2013. 96 (2014). [4] William Morrison, MD , international journal of additive manufacturing technologies; July 23, (2018) 68-74. [5] C K Basavaraj1 and M Vishwas2, Studies on the effect of fused deposition modeling, “IOP Conference Series: Materials Science and Engineering,”149. [6] Shivraj Yeole, P.Chennakesava Sai. Fused deposition modelling insights.” International Conference on Advances in Design & Manufacturing (2014)”1345-1350.