Advanced Manufacturing Technology for Medical Applications

Ian Gibson is the editor of Advanced Manufacturing Technology for Medical Applications: Reverse Engineering, Software Conversion and Rapid Prototyping, published by Wiley.

• Contributors xi1 Rapid Prototyping for Medical Applications 1Ian Gibson1.1 Overview 11.2 Workshop on Medical Applications for Reverse Engineering and Rapid Prototyping 21.3 Purpose of This Chapter (Overview) 31.4 Background on Rapid Prototyping 31.5 Stereolithography and Other Resin-type Systems 61.6 Fused Deposition Modelling and Selective Laser Sintering 71.7 Droplet/Binder Systems 91.8 Related Technology: Microsystems and Direct Metal Systems 101.9 File Preparation 111.10 Relationship with Other Technologies 121.11 Disadvantages with RP for Medical Applications 131.12 Summary 14Bibliography 142 Role of Rapid Digital Manufacture in Planning and Implementation of Complex Medical Treatments 15Andrew M. Christensen and Stephen M. Humphries2.1 Introduction 162.2 Primer on Medical Imaging 162.3 Surgical Planning 182.3.1 Virtual planning 182.3.2 Implementation of the plan 202.4 RDM in Medicine 222.4.1 RP-generated anatomical models 222.4.2 Custom treatment devices with ADM 262.5 The Future 282.6 Conclusion 29References 293 Biomodelling 31P. D’Urso3.1 Introduction 313.2 Surgical Applications of Real Virtuality 323.2.1 Cranio-maxillofacial biomodelling 333.2.1.1 Integration of biomodels with dental castings 343.2.1.2 Use of biomodels to shape maxillofacial implants 353.2.1.3 Use of biomodels to prefabricate templates and splints 353.2.1.4 Use of biomodels in restorative prosthetics 363.2.2 Use of real virtuality in customized cranio-maxillofacial prosthetics 363.2.2.1 Computer mirroring techniques for the generation of prostheses 383.2.2.2 Results of implantation 393.2.2.3 Advantages of prefabricated customized cranioplastic implants 393.2.3 Biomodel-guided stereotaxy 393.2.3.1 Development of stereotaxy 403.2.3.2 Development of biomodel-guided stereotactic surgery 403.2.3.3 Biomodel-guided stereotactic surgery with a template and markers 413.2.3.4 Biomodel-guided stereotactic surgery using the D’Urso frame 423.2.3.5 Utility of biomodel-guided stereotactic surgery 433.2.4 Vascular biomodelling 443.2.4.1 Biomodelling from CTA 443.2.4.2 Biomodelling from MRA 453.2.4.3 Clinical applications of vascular biomodels 453.2.4.4 Vascular biomodelling: technical note 463.2.5 Skull-base tumour surgery 463.2.6 Spinal surgery 483.2.6.1 Spinal biomodel stereotaxy 483.2.6.2 Technical considerations in spinal biomodelling 503.2.7 Orthopaedic biomodelling 503.3 Case Studies 51References 554 Three-dimensional Data Capture and Processing 59W. Feng, Y. F. Zhang, Y. F. Wu and Y. S. Wong4.1 Introduction 604.2 3D Medical Scan Process 614.2.1 3D scanning 614.2.1.1 Computed tomography imaging and its applications 614.2.1.2 Magnetic resonance imaging and its applications 634.2.1.3 Ultrasound imaging and its applications 644.2.1.4 3D laser scanning 654.2.2 3D reconstruction 654.3 RE and RP in Medical Application 674.3.1 Proposed method for RP model construction from scanned data 684.3.2 Reconstruction software 694.3.3 Accuracy issues 704.4 Applications of Medical Imaging 714.5 Case Study 724.5.1 Case study with CT/MR scanned data 724.5.2 Case studies for RE and RP 744.6 Conclusions 76References 76Bibliography 765 Software for Medical Data Transfer 79Ellen Dhoore5.1 Introduction 795.2 Medical Imaging: from Medical Scanner to 3D Model 795.2.1 Introduction 795.2.2 Mimics® 805.2.2.1 Basic functionality of Mimics 805.2.2.2 Additional modules in Mimics 825.3 Computer Approach in Dental Implantology 925.3.1 Introduction 925.3.2 Virtual 3D planning environment: SimPlant® 925.3.3 Guide to accurate implant treatment: SurgiGuide® 935.3.3.1 General concept of SurgiGuide® 935.3.3.2 Different types of SurgiGuide® 945.3.3.3 Immediate SmileTM: temporary prosthesis for truly ‘immediate’ loading 1005.4 Conclusions 102Bibliography 1036 BioBuild Software 105Robert Thompson, Dr Gian Lorenzetto and Dr Paul D'Urso6.1 Introduction 1056.2 BioBuild Paradigm 1096.2.1 Importing a dataset 1106.2.2 Volume reduction 1126.2.3 Anatomical orientation confirmation 1126.2.4 Volume inspection and intensity thresholding 1126.2.4.1 Intensity thresholding 1136.2.4.2 Display options 1146.2.5 Volume editing 1146.2.5.1 Connectivity options 1156.2.5.2 Volume morphology 1156.2.5.3 Region morphology 1166.2.5.4 Volume algebra 1166.2.5.5 Labels 1176.2.5.6 Volume transformations 1176.2.6 Image processing 1186.2.7 Build orientation optimization 1186.2.8 3D visualization 1196.2.9 RP file generation 1196.3 Future Enhancements 1206.3.1 Direct volume rendering (DVR) 1206.4 Conclusion 121References 1217 Generalized Artificial Finger Joint Design Process Employing Reverse Engineering 123I. Gibson and X. P. Wang7.1 Introduction 1237.1.1 Structure of a human finger joint 1237.1.2 Rheumatoid arthritis disease 1237.1.3 Finger joint replacement design 1247.1.4 Requirements for new finger joint design 1257.1.5 Research objectives 1267.2 Supporting Literature 1277.2.1 Previous prosthetic designs 1277.2.2 More recent designs 1287.2.3 Development of a new design 1287.2.4 Need for a generalized finger joint prosthesis 1297.3 Technological Supports for the Prosthesis Design 1307.3.1 Reverse engineering 1307.3.2 Comparison of different imaging techniques 1317.3.3 Engineering and medical aspects 1317.3.4 NURBS design theory 1317.4 Proposed Methodology 1327.4.1 Finger joint model preparation 1327.4.2 Finger joint digitization 1337.4.3 Surface reconstruction in paraform 1357.4.4 Curve feature extraction 1357.4.5 Database construction and surface generalization 1357.4.6 Review of the procedure 1367.5 Finger Joint Surface Modelling and Feature Extraction 1367.5.1 Data acquisition of the bone samples 1367.5.2 Finger joint surface reconstruction 1377.5.3 NURBS curve and feature extraction 1387.5.3.1 NURBS curve extraction from the PP head 1387.5.3.2 NURBS curve feature extraction from the PP and MP base 1417.5.3.3 Discussion on curve feature extraction 1427.5.4 Automatic surface reconstruction and feature extraction 1437.5.4.1 Automated identification of the bearing surface 1437.5.4.2 Automated feature extraction 1437.6 Database Construction and Surface Generalization 1457.6.1 Finger joint database construction 1457.6.1.1 Statistical dimension analysis 1457.6.1.2 PP head geometrical features 1507.6.2 Generalized finger joint surface reconstruction 1557.7 Conclusions 159Acknowledgements 161References 1618 Scaffold-based Tissue Engineering – Design and Fabrication of Matrices Using Solid Freeform Fabrication Techniques 163Dietmar W. Hutmacher8.1 Background 1648.2 Introduction 1678.3 Systems Based on Laser and UV Light Sources 1678.3.1 Stereolithography apparatus (SLA) 1678.3.2 Selective laser sintering (SLS) 1708.3.3 Laminated object manufacturing (LOM) 1718.3.4 Solid ground curing (SGC) 1718.4 Systems Based on Printing Technology 1728.4.1 Three-dimensional printing (3DP) 1728.5 Systems Based on Extrusion/Direct Writing 1768.6 Indirect SFF 1808.7 Robotic and Mechatronically Controlled Systems 1828.8 Conclusions 185References 1869 Direct Fabrication of Custom Orthopedic Implants Using Electron Beam Melting Technology 191Ola L. A. Harrysson and Denis R. Cormier9.1 Introduction 1919.2 Literature Review 1929.2.1 Custom joint replacement implants 1929.2.2 Custom bone plates and implants 1969.3 Electron Beam Melting Technology 1999.4 Direct Fabrication of Titanium Orthopedic Implants 2019.4.1 EBM fabrication of custom knee implants 2019.4.2 EBM fabrication of custom bone plates 2029.4.3 Direct fabrication of bone ingrowth surfaces 2039.5 Summary and Conclusions 204References 20510 Modelling, Analysis and Fabrication of Below-knee Prosthetic Sockets Using Rapid Prototyping 207J. Y. H. Fuh, W. Feng and Y. S. Wong10.1 Introduction 20810.1.1 Process of making the below-knee artificial prosthesis 20810.1.1.1 Shaping of the positive mould 20810.1.1.2 Fabrication of the prosthesis 20910.1.2 Modelling, analysis and fabrication 21010.2 Computer-Facilitated Approach 21110.2.1 CAD modelling 21110.2.2 Finite element analysis (FEA) 21310.2.2.1 Geometries 21310.2.2.2 Boundary conditions 21310.2.2.3 Loading conditions 21310.2.2.4 Analysis 21410.3 Experiments 21510.4 Results and Discussions 21610.5 Rapid Socket Manufacturing Machine (RSMM) 21910.5.1 RSMM design considerations 22010.5.1.1 File format 22010.5.1.2 Nozzle 22010.5.1.3 System accuracy 22110.5.2 Overview of the RSMM 22110.5.3 Clinical test 22310.5.4 Future work 22410.6 Conclusions 225Acknowledgements 225References 225Bibliography 22611 Future Development of Medical Applications for Advanced Manufacturing Technology 227Ian Gibson11.1 Introduction 22711.2 Scanning Technology 22811.3 RP Technology 22911.4 Direct Manufacture 23011.5 Tissue Engineering 23111.6 Business 232Index 233

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