Abstract
The use of external fixation devices is considered a valuable approach for the treatment of bone fractures, providing proper alignment to fractured fragments and maintaining fracture stability during the healing process. The need for external fixation devices has increased due to an aging population and increased trauma incidents. The design and fabrication of external fixations are major challenges since the shape and size of the defect vary, as well as the geometry of the human limb. This requires fully personalized external fixators to improve its fit and functionality. This paper presents a methodology to design personalized lightweight external fixator devices for additive manufacturing. This methodology comprises data acquisition, Computer tomography (CT) imaging analysis and processing, Computer Aided Design (CAD) modelling and two methods (imposed predefined patterns and topology optimization) to reduce the weight of the device. Finite element analysis with full factorial design of experiments were used to determine the optimal combination of designs (topology optimization and predefined patterns), materials (polylactic acid, acrylonitrile butadiene styrene, and polyamide) and thickness (3, 4, 5 and 6 mm) to maximize the strength and stiffness of the fixator, while minimizing its weight. The optimal parameters were found to correspond to an external fixator device optimized by topology optimization, made in polylactic acid with 4 mm thickness.
Highlights
Introduction published maps and institutional affilMusculoskeletal disorders and bone diseases resulting from aging or traumatic problems due to car accidents, wars and natural disasters represent one of the major health concerns in the world [1,2]
The aim of this study was to develop an integrated approach using a set of techniques including Computer tomography (CT) imaging, computer aided design (CAD), finite element analysis (FEA) and design methods to create a custom-made lightweight external fixator device aiming to be produced by additive manufacturing
The number of conplanes has an impact on both design accuracy and processing time, which increase by sidered planes has an impact on both design accuracy and processing time, which increase
Summary
Introduction published maps and institutional affilMusculoskeletal disorders and bone diseases resulting from aging or traumatic problems due to car accidents, wars and natural disasters represent one of the major health concerns in the world [1,2]. Bone fractures can be treated conservatively or using internal and/or external fixators depending on how extensive the damage is. Internal fixators such as fixation plates and intramedullary rods or nails are made in biocompatible metallic alloys and prone to some stress shielding problems [3]. External fracture fixation is a common and well-established method used by orthopedic surgeons to treat musculoskeletal injuries [5,6,7] This method is widely used for the treatment of different injuries or conditions such as compound fractures, acute fractures, soft tissue injuries, non-unions, delayed union, mal-union, and limb lengthening [8,9]
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