Title: Design for manufacturing of custom-made femoral stem using CT data and rapid prototyping technology

Authors: Farid Abbaszadeh, Sadegh Rahmati, Hossein Kheirollahi, Farzam Farahmand

Addresses: Young Researchers Club, Science and Research Branch, Islamic Azad University, Tehran, Iran. ' Manufacturing Engineering Group, Majlesi Branch, Islamic Azad University (IAU), Isfahan, Iran. ' Department of Mechanical Engineering, Imam Hossein University, Tehran, Iran. ' Department of Mechanical Engineering, Sharif University of Technology, Tehran, Iran and RCSTIM, Tehran University of Medical Sciences, Tehran, Iran

Abstract: Rapid prototyping (RP) applications have an increasing trend, making the future of RP more and more promising. These applications may include design, development, and manufacture of medical devices and instrumentation, as well as prosthesis design, anatomical modelling, surgical planning and prosthesis fabrication. This paper provides a new methodology for design of custom-made femoral stem, providing high accuracy of femoral canal reconstruction via 3D modelling of femoral stem with optimal fill and fit. The result of this methodology is optimised load transfer, minimum stem micromotion, increase in initial stability and extended durability. In addition to the above, the possibility of combining the stem with different modular necks to satisfy any type of femoral head shapes and facilitating the communication between designer and surgeon are other advantages. Applying RP technology has facilitated manufacturing of complex 3D femoral stems and has lead into time and economical benefits.

Keywords: MRP; medical rapid prototyping; custom-made femoral stems; fill and fit; femoral canal reconstruction; 3D modelling; femoral head shapes.

DOI: 10.1504/IJRAPIDM.2011.040690

International Journal of Rapid Manufacturing, 2011 Vol.2 No.1/2, pp.76 - 91

Published online: 16 Jun 2011 *

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