Titanium based cranial reconstruction using incremental sheet forming

B Lu,J Chen,H Long,S Q Shi,H Ou

doi:10.1007/s12289-014-1205-8

Abstract

In this paper, we report recent work in cranial plate manufacturing using incremental sheet forming (ISF) process. With a typical cranial shape, the ISF process was used to manufacture the titanium cranial shape by using different ISF tooling solutions with and without backing plates. Detailed evaluation of the ISF process including material deformation and thinning, geometric accuracy and surface finish was conducted by using a combination of experimental testing and Finite Element (FE) simulation. The results show that satisfactory cranial shape can be achieved with sufficient accuracy and surface finish by using a feature based tool path generation method and new ISF tooling design. The results also demonstrate that the ISF based cranial reconstruction has the potential to achieve considerable lead time reduction as compared to conventional methods for cranial plate manufacturing. This outcome indicates that there is a potential for the ISF process to achieve technological advances and economic benefits as well as improvement to quality of life.

Highlights

Cranioplasty is a surgical procedure for the repair of deformity of a human skull due to brain tumour, stroke or traumatic injuries
Cranioplasty surgical procedures may be conducted by using autografting and allografting or alloplastic materials
This paper aims to study the feasibility of manufacturing customized titanium cranial plates by using the incremental sheet forming (ISF) approach

Summary

Introduction

Cranioplasty is a surgical procedure for the repair of deformity of a human skull due to brain tumour, stroke or traumatic injuries. Cranioplasty surgery does offer cosmetic and sometimes lifesaving benefits and give relief to psychological drawbacks and improve the quality of life of patients [1]. Cranioplasty surgical procedures may be conducted by using autografting (implant taken from patient own body) and allografting (implant taken from a donor body) or alloplastic (non-biologic such as polymeric and metallic) materials. Non-metallic materials such as Polymethylmethacrylate (PMMA), Polyetheretherketone (PEEK) and Hydroxyapatite, and metallic substitutes such as stainless steel and titanium, alloplastic materials are commonly used in cranioplasty surgeries. The selection of cranioplasty materials is normally based on the requirements of such as biocompatibility, material properties and surgeon’s experience and preference. Technical readiness for clinical application, short lead time, low cost and ease of manufacture for alloplastic cranioplasty are important considerations [2]

Objectives

Methods

Findings

Conclusion