Title: Diaphyseal femoral fracture: 3D biomodel and intramedullary nail created by additive manufacturing

Authors: M.G. Fernandes; J.L. Alves; E.M.M. Fonseca

Addresses: INEGI, Faculty of Engineering, University of Porto, Campus da FEUP, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal ' Department of Mechanical Engineering, INEGI, Faculty of Engineering, University of Porto, Campus da FEUP, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal ' Department of Applied Mechanics, LAETA, INEGI/UMNMEE, Polytechnic Institute of Bragança, Campus de Santa Apolónia, 5300-253 Bragança, Portugal

Abstract: The aim of the present work was to explore the feasibility of different additive manufacturing techniques applied in design, diagnosis and planning of a locked intramedullary nail used in the diaphyseal femoral fractures. Using a clinical case study of a femoral diaphysis fracture, a biomodel was developed to simulate the osseointegration bone-implant. The biomechanical analysis was performed using the finite element method and different additive manufacturing techniques were applied, particularly the full colour printing to obtain the colour levels related to von Mises stresses. The biomodel and all applied prototyping techniques have proved to be important, since they allow fast reconstruction of layered prototyping models from point cloud data with a shape errors control. In surgical procedures these models can provide practice simulators, procedure guides and models against which to measure progress by helping health professionals on an accurate and safe surgical planning.

Keywords: additive manufacturing; biomodelling; intramedullary nails; numerical simulation; diaphyseal femoral fractures; 3D modelling; clinical case study; osseointegration bone implants; biomechanics; finite element method; FEM; colour printing; von Mises stresses; surgical planning; layered manufacturing; stereolithography; fused deposition modelling; FDM; 3D printing; bioengineering.

DOI: 10.1504/IJMATEI.2016.079556

International Journal of Materials Engineering Innovation, 2016 Vol.7 No.2, pp.130 - 142

Received: 28 Nov 2015
Accepted: 20 Jan 2016

Published online: 23 Sep 2016 *

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