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CONTENTS 1 RAPID PROTOTYPING FOR MEDICAL APPLICATIONS 1 1 1 OVERVIEW 1 1 2 WORKSHOP ON MEDICAL APPLICATIONS FOR REVERSE ENGINEERING AND RAPID PROTOTYPING 2 1 3 PURPOSE OF THIS CHAPTER OVERVIEW 3 1 4 BACKGROUND ON RAPID PROTOTYPING 3 1 5 STEREOLITHOGRAPHY AND OTHER RESIN TYPE SYSTEMS 6 1 6 FUSED DEPOSITION MODELLING AND SELECTIVE LASER SINTERING 7 1 7 DROPLET BINDER SYSTEMS 9 1 8 RELATED TECHNOLOGY MICROSYSTEMS AND DIRECT METAL SYSTEMS 10 1 9 FILE PREPARATION 11 1 10 RELATIONSHIP WITH OTHER TECHNOLOGIES 12 1 11 DISADVANTAGES WITH RP FOR MEDICAL APPLICATIONS 13 1 12 SUMMARY 14 BIBLIOGRAPHY 14 2 ROLE OF RAPID DIGITAL MANUFACTURE IN PLANNING AND IMPLEMENTATION OF COMPLEX MEDICAL TREATMENTS 15 2 1 INTRODUCTION 16 2 2 PRIMER ON MEDICAL IMAGING 16 2 3 SURGICAL PLANNING 18 2 3 1 VIRTUAL PLANNING 18 2 3 2 IMPLEMENTATION OF THE PLAN 20 2 4 RDM IN MEDICINE 22 2 4 1 RP GENERATED ANATOMICAL MODELS 22 2 4 2 CUSTOM TREATMENT DEVICES WITH ADM 26 2 5 THE FUTURE 28 2 6 CONCLUSION 29 REFERENCES 29 V 3 BIOMODELLING 31 3 1 INTRODUCTION 31 3 2 SURGICAL APPLICATIONS OF REAL VIRTUALITY 32 3 2 1 CRANIO MAXILLOFACIAL BIOMODELLING 33 3 2 1 1 INTEGRATION OF BIOMODELS WITH DENTAL CASTINGS 34 3 2 1 2 USE OF BIOMODELS TO SHAPE MAXILLOFACIAL IMPLANTS 35 3 2 1 3 USE OF BIOMODELS TO PREFABRICATE TEMPLATES AND SPLINTS 35 3 2 1 4 USE OF BIOMODELS IN RESTORATIVE PROSTHETICS 36 3 2 2 USE OF REAL VIRTUALITY IN CUSTOMIZED CRANIO MAXILLOFACIAL PROSTHETICS 36 3 2 2 1 COMPUTER MIRRORING TECHNIQUES FOR THE GENERATION OF PROSTHESES 38 3 2 2 2 RESULTS OF IMPLANTATION 39 3 2 2 3 ADVANTAGES OF PREFABRICATED CUSTOMIZED CRANIOPLASTIC IMPLANTS 39 3 2 3 BIOMODEL GUIDED STEREOTAXY 39 3 2 3 1 DEVELOPMENT OF STEREOTAXY 40 3 2 3 2 DEVELOPMENT OF BIOMODEL GUIDED STEREOTACTIC SURGERY 40 3 2 3 3 BIOMODEL GUIDED STEREOTACTIC SURGERY WITH A TEMPLATE AND MARKERS 41 3 2 3 4 BIOMODEL GUIDED STEREOTACTIC SURGERY USING THE D URSO FRAME 42 3 2 3 5 UTILITY OF BIOMODEL GUIDED STEREOTACTIC SURGERY 43 3 2 4 VASCULAR BIOMODELLING 44 3 2 4 1 BIOMODELLING FROM CTA 44 3 2 4 2 BIOMODELLING FROM MRA 45 3 2 4 3 CLINICAL APPLICATIONS OF VASCULAR BIOMODELS 45 3 2 4 4 VASCULAR BIOMODELLING TECHNICAL NOTE 46 3 2 5 SKULL BASE TUMOUR SURGERY 46 3 2 6 SPINAL SURGERY 48 3 2 6 1 SPINAL BIOMODEL STEREOTAXY 48 3 2 6 2 TECHNICAL CONSIDERATIONS IN SPINAL BIOMODELLING 50 3 2 7 ORTHOPAEDIC BIOMODELLING 50 3 3 CASE STUDIES 51 REFERENCES 55 4 THREE DIMENSIONAL DATA CAPTURE AND PROCESSING 59 4 1 INTRODUCTION 60 4 2 3D MEDICAL SCAN PROCESS 61 4 2 1 3D SCANNING 61 4 2 1 1 COMPUTED TOMOGRAPHY IMAGING AND ITS APPLICATIONS 61 4 2 1 2 MAGNETIC RESONANCE IMAGING AND ITS APPLICATIONS 63 4 2 1 3 ULTRASOUND IMAGING AND ITS APPLICATIONS 64 4 2 1 4 3D LASER SCANNING 65 4 2 2 3D RECONSTRUCTION 65 4 3 RE AND RP IN MEDICAL APPLICATION 67 4 3 1 PROPOSED METHOD FOR RP MODEL CONSTRUCTION FROM SCANNED DATA 68 4 3 2 RECONSTRUCTION SOFTWARE 69 4 3 3 ACCURACY ISSUES 70 4 4 APPLICATIONS OF MEDICAL IMAGING 71 4 5 CASE STUDY 72 4 5 1 CASE STUDY WITH CT MR SCANNED DATA 72 4 5 2 CASE STUDIES FOR RE AND RP 74 4 6 CONCLUSIONS 76 REFERENCES 76 BIBLIOGRAPHY 76 5 SOFTWARE FOR MEDICAL DATA TRANSFER 79 5 1 INTRODUCTION 79 5 2 MEDICAL IMAGING FROM MEDICAL SCANNER TO 3D MODEL 79 5 2 1 INTRODUCTION 79 5 2 2 MIMICS 80 5 2 2 1 BASIC FUNCTIONALITY OF MIMICS 80 5 2 2 2 ADDITIONAL MODULES IN MIMICS 82 5 3 COMPUTER APPROACH IN DENTAL IMPLANTOLOGY 92 5 3 1 INTRODUCTION 92 5 3 2 VIRTUAL 3D PLANNING ENVIRONMENT SIMPLANT 92 5 3 3 GUIDE TO ACCURATE IMPLANT TREATMENT SURGIGUIDE 93 5 3 3 1 GENERAL CONCEPT OF SURGIGUIDE 93 5 3 3 2 DIFFERENT TYPES OF SURGIGUIDE 94 5 3 3 3 IMMEDIATE SMILETM TEMPORARY PROSTHESIS FOR TRULY IMMEDIATE LOADING 100 5 4 CONCLUSIONS 102 BIBLIOGRAPHY 103 6 BIOBUILD SOFTWARE 105 6 1 INTRODUCTION 105 6 2 BIOBUILD PARADIGM 109 6 2 1 IMPORTING A DATASET 110 6 2 2 VOLUME REDUCTION 112 6 2 3 ANATOMICAL ORIENTATION CON RMATION 112 6 2 4 VOLUME INSPECTION AND INTENSITY THRESHOLDING 112 6 2 4 1 INTENSITY THRESHOLDING 113 6 2 4 2 DISPLAY OPTIONS 114 6 2 5 VOLUME EDITING 114 6 2 5 1 CONNECTIVITY OPTIONS 115 6 2 5 2 VOLUME MORPHOLOGY 115 6 2 5 3 REGION MORPHOLOGY 116 6 2 5 4 VOLUME ALGEBRA 116 6 2 5 5 LABELS 117 6 2 5 6 VOLUME TRANSFORMATIONS 117 6 2 6 IMAGE PROCESSING 118 6 2 7 BUILD ORIENTATION OPTIMIZATION 118 6 2 8 3D VISUALIZATION 119 6 2 9 RP LE GENERATION 119 6 3 FUTURE ENHANCEMENTS 120 6 3 1 DIRECT VOLUME RENDERING DVR 120 6 4 CONCLUSION 121 REFERENCES 121 7 GENERALIZED ARTI CIAL FINGER JOINT DESIGN PROCESS EMPLOYING REVERSE ENGINEERING 123 7 1 INTRODUCTION 123 7 1 1 STRUCTURE OF A HUMAN NGER JOINT 123 7 1 2 RHEUMATOID ARTHRITIS DISEASE 123 7 1 3 FINGER JOINT REPLACEMENT DESIGN 124 7 1 4 REQUIREMENTS FOR NEW NGER JOINT DESIGN 125 7 1 5 RESEARCH OBJECTIVES 126 7 2 SUPPORTING LITERATURE 127 7 2 1 PREVIOUS PROSTHETIC DESIGNS 127 7 2 2 MORE RECENT DESIGNS 128 7 2 3 DEVELOPMENT OF A NEW DESIGN 128 7 2 4 NEED FOR A GENERALIZED NGER JOINT PROSTHESIS 129 7 3 TECHNOLOGICAL SUPPORTS FOR THE PROSTHESIS DESIGN 130 7 3 1 REVERSE ENGINEERING 130 7 3 2 COMPARISON OF DIFFERENT IMAGING TECHNIQUES 131 7 3 3 ENGINEERING AND MEDICAL ASPECTS 131 7 3 4 NURBS DESIGN THEORY 131 7 4 PROPOSED METHODOLOGY 132 7 4 1 FINGER JOINT MODEL PREPARATION 132 7 4 2 FINGER JOINT DIGITIZATION 133 7 4 3 SURFACE RECONSTRUCTION IN PARAFORM 135 7 4 4 CURVE FEATURE EXTRACTION 135 7 4 5 DATABASE CONSTRUCTION AND SURFACE GENERALIZATION 135 7 4 6 REVIEW OF THE PROCEDURE 136 7 5 FINGER JOINT SURFACE MODELLING AND FEATURE EXTRACTION 136 7 5 1 DATA ACQUISITION OF THE BONE SAMPLES 136 7 5 2 FINGER JOINT SURFACE RECONSTRUCTION 137 7 5 3 NURBS CURVE AND FEATURE EXTRACTION 138 7 5 3 1 NURBS CURVE EXTRACTION FROM THE PP HEAD 138 7 5 3 2 NURBS CURVE FEATURE EXTRACTION FROM THE PP AND MP BASE 141 7 5 3 3 DISCUSSION ON CURVE FEATURE EXTRACTION 142 7 5 4 AUTOMATIC SURFACE RECONSTRUCTION AND FEATURE EXTRACTION 143 7 5 4 1 AUTOMATED IDENTI CATION OF THE BEARING SURFACE 143 7 5 4 2 AUTOMATED FEATURE EXTRACTION 143 7 6 DATABASE CONSTRUCTION AND SURFACE GENERALIZATION 145 7 6 1 FINGER JOINT DATABASE CONSTRUCTION 145 7 6 1 1 STATISTICAL DIMENSION ANALYSIS 145 7 6 1 2 PP HEAD GEOMETRICAL FEATURES 150 7 6 2 GENERALIZED NGER JOINT SURFACE RECONSTRUCTION 155 7 7 CONCLUSIONS 159 ACKNOWLEDGEMENTS 161 REFERENCES 161 8 SCAFFOLD BASED TISSUE ENGINEERING DESIGN AND FABRICATION OF MATRICES USING SOLID FREEFORM FABRICATION TECHNIQUES 163 8 1 BACKGROUND 164 8 2 INTRODUCTION 167 8 3 SYSTEMS BASED ON LASER AND UV LIGHT SOURCES 167 8 3 1 STEREOLITHOGRAPHY APPARATUS SLA 167 8 3 2 SELECTIVE LASER SINTERING SLS 170 8 3 3 LAMINATED OBJECT MANUFACTURING LOM 171 8 3 4 SOLID GROUND CURING SGC 171 8 4 SYSTEMS BASED ON PRINTING TECHNOLOGY 172 8 4 1 THREE DIMENSIONAL PRINTING 3DP 172 8 5 SYSTEMS BASED ON EXTRUSION DIRECT WRITING 176 8 6 INDIRECT SFF 180 8 7 ROBOTIC AND MECHATRONICALLY CONTROLLED SYSTEMS 182 8 8 CONCLUSIONS 185 REFERENCES 186 9 DIRECT FABRICATION OF CUSTOM ORTHOPEDIC IMPLANTS USING ELECTRON BEAM MELTING TECHNOLOGY 191 9 1 INTRODUCTION 191 9 2 LITERATURE REVIEW 192 9 2 1 CUSTOM JOINT REPLACEMENT IMPLANTS 192 9 2 2 CUSTOM BONE PLATES AND IMPLANTS 196 9 3 ELECTRON BEAM MELTING TECHNOLOGY 199 9 4 DIRECT FABRICATION OF TITANIUM ORTHOPEDIC IMPLANTS 201 9 4 1 EBM FABRICATION OF CUSTOM KNEE IMPLANTS 201 9 4 2 EBM FABRICATION OF CUSTOM BONE PLATES 202 9 4 3 DIRECT FABRICATION OF BONE INGROWTH SURFACES 203 9 5 SUMMARY AND CONCLUSIONS 204 REFERENCES 205 10 MODELLING ANALYSIS AND FABRICATION OF BELOW KNEE PROSTHETIC SOCKETS USING RAPID PROTOTYPING 207 10 1 INTRODUCTION 208 10 1 1 PROCESS OF MAKING THE BELOW KNEE ARTI CIAL PROSTHESIS 208 10 1 1 1 SHAPING OF THE POSITIVE MOULD 208 10 1 1 2 FABRICATION OF THE PROSTHESIS 209 10 1 2 MODELLING ANALYSIS AND FABRICATION 210 10 2 COMPUTER FACILITATED APPROACH 211 10 2 1 CAD MODELLING 211 10 2 2 FINITE ELEMENT ANALYSIS FEA 213 10 2 2 1 GEOMETRIES 213 10 2 2 2 BOUNDARY CONDITIONS 213 10 2 2 3 LOADING CONDITIONS 213 10 2 2 4 ANALYSIS 214