Field Of Additive Manufacturing Research Articles

Research and implementation of large-area sintering technology based on image-shaped laser

Purpose Selective laser sintering (SLS) is an essential technology in the field of additive manufacturing. However, SLS technology is limited by the traditional point-laser sintering method and has reached the bottleneck of efficiency improvement. This study aims to develop an image-shaped laser sintering (ISLS) system based on a digital micromirror device (DMD) to address this problem. The ISLS system uses an image-shaped laser light source with a size of 16 mm × 25.6 mm instead of the traditional SLS point-laser light source. Design/methodology/approach The ISLS system achieves large-area image-shaped sintering of polymer powder materials by moving the laser light source continuously in the x-direction and updating the sintering pattern synchronously, as well as by overlapping the splicing of adjacent sintering areas in the y-direction. A low-cost composite powder suitable for the ISLS system was prepared using polyether sulfone (PES), pinewood and carbon black (CB) powders as raw materials. Large-sized samples were fabricated using composite powder, and the microstructure, dimensional accuracy, geometric deviation, density, mechanical properties and feasible feature sizes were evaluated. Findings The experimental results demonstrate that the ISLS system is feasible and can print large-sized parts with good dimensional accuracy, acceptable geometric deviations, specific small-scale features and certain density and mechanical properties. Originality/value This study has achieved the transition from traditional point sintering mode to image-shaped surface sintering mode. It has provided a new approach to enhance the system performance of traditional SLS.

Manufacturing of Brake Pads and Brake Shoes Through Additive Manufacturing with Boron Carbide (B4C) and Molybdenum Disulfide (MoS2) as Additives

Abstract: An essential component of car performance and safety is the production of brake shoes and pads. This study investigates how to improve these components by incorporating innovative materials using additive manufacturing techniques. Because of their special qualities, molybdenum disulfide (MoS2) and boron carbide (B4C) are used as additives. MoS2, which is well-known for its solid lubricating qualities, seeks to improve the frictional properties, while B4C, which is recognized for its extraordinary hardness, is added to increase wear resistance. Brake component performance can be maximized by precisely controlling the material composition and complex designs through the use of additive manufacturing. The combination of B4C and MoS2 provides a well-rounded solution by tackling the wear and friction issues that are essential for efficient braking. In order to obtain increased frictional stability, decreased wear rates, and greater durability, this study looks into the best ratios and distribution of these additives. This study seeks to contribute to the development of next generation brake systems, ensuring improved safety, efficiency, and lifetime in automotive applications by utilizing modern manufacturing techniques and combining B4C and MoS2. The results are anticipated to have an impact on the production of high-performance components with customized material qualities in the automobile industry as well as the larger field of additive manufacturing.

After 3D Printing, What's Next: Discovering Scientific Trends of 4D Printing

he field of additive manufacturing has seen the rise of 3D Printing and 4D Printing as noteworthy subjects of research. This study highlights the advancements in advanced Printing techniques. To identify, evaluate, and analyze the existing literature on this subject, the research followed the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) methodology, focusing on documents indexed in the Elsevier Scopus database. Through bibliometric analysis (BA), including co-authorship, keyword co-occurrence, and citations, the research landscape and scientific progress in this area were examined. The analysis revealed that a total of 1,638 documents have been published and indexed on this topic since its inception. The search was conducted on February 17, 2023, at 2:30 AM +8 GMT. The results indicated that articles are the primary form of publication, with a strong emphasis on Materials Science, Engineering, and Chemistry as the favored thematic subjects in the published works. Among the various sources of publications, ACS Applied Materials and Interfaces, published by ACS Publications, emerged as the most influential. On the research leadership front, Gladman A. Sydney, affiliated with Harvard University, was identified as the most influential lead researcher in this domain. Further examination revealed that prolific authors in this field are primarily associated with institutions in China, the United States, India, the United Kingdom, and Singapore. In conclusion, the findings highlight that the trend of 4D Printing within the scientific community is still in a phase of ongoing development.

Revolutionizing Three-Dimensional Printing: Enhancing Quality Assurance and Point-of-Care Integration through Instrumentation.

Three-dimensional printing in the field of additive manufacturing shows potential for customized medicines and solving gaps in paediatric formulations. Despite successful clinical trials, 3D printing use in pharmaceutical point-of-care is limited by regulatory loopholes and a lack of Pharmacopoeia guidelines to ensure quality. Semi-solid extrusion is a 3D printing technology that stands out for its versatility, but understanding the fluid dynamics of the semi-solid mass is critical. The aim of this research is to look into the advantages of instrumenting a 3D printer with a semi-solid extrusion motor-driven printhead, which is able to record the printing pressure over time, for in situ characterization of the semi-solid mass and quality evaluation of dosage forms. Four formulations using hydrochlorothiazide as the active pharmaceutical ingredient and several excipients were used. Their flow properties were studied at different printing speeds and temperatures using traditional techniques (rheometer and Texture Analyzer) and the proposed semi-solid extrusion motor-driven printhead incorporated into a printing platform. In addition, the influence of printing speed in the printing process was also evaluated by the study of printing pressure and printlet quality. The results demonstrated the similarities between the use of a Texture Analyzer and the semi-solid extrusion motor-driven. However, the latter enables temperature selection and printing speed in accordance with the printing process which are critical printing parameters. In addition, due to the incorporation of a sensor, it was possible to conclude, for the first time, that there is a link between changes in essential printing parameters like printing speed or formulations and variations in printing pressure and printlet quality attributes such as the energy require to obtain a single dosage unit, weight or diameter. This breakthrough holds a lot of potential for assuring the quality of 3D printing dosage forms and paving the way for their future incorporation into point-of-care settings.

Directed energy deposition of PH 13–8 Mo stainless steel: microstructure and mechanical property analysis

Laser metal deposition (LMD) is of the directed energy deposition (DED) process which is widely used for producing large-scale, dense, and functional parts in the field of additive manufacturing (AM). This research work investigates the microstructure and mechanical properties of PH 13–8 Mo martensitic stainless-steel parts produced via LMD. The workshop trials were conducted using an LMD system collaborated with a robotic arm to deposit single-track thin walls and horizontal blocks. The microstructural characteristics of the additively manufactured parts were analyzed using an optical microscope. The mechanical properties were evaluated through hardness measurements and uniaxial tensile tests. The influence of energy density and powder deposition density on the characteristic geometry of straight walls was also investigated. The microstructural analysis showed that the microstructure consisted of columnar dendrites that grew epitaxially from the substrate, with primary austenite cells containing intercellular ferrite and martensite laths that were roughly parallel with the retained austenite. When the energy density increased from 43 to 86 J/mm2 (a doubling of energy density), there was an increase in secondary dendritic arm spacing (SDAS) by approximately 250% in the first layer and approximately 90% in the top layer. The difference in SDAS change between the first and top layers can be attributed to the difference in cooling rates experienced by each layer during the additive manufacturing process. Increasing powder deposition density from 0.5 to 1 g/min results in a decrease in porosity from 3% to less than 1% and an increase in strength from 800 to over 1000 MPa. The hardness of the deposits was found to range from 300 to 400 HV. This variation in hardness can be attributed to differences in microstructure resulting from changes in cooling rates at different heights.

Fundamental scaling relationships in additive manufacturing and their implications for future manufacturing and bio-manufacturing systems

The field of additive manufacturing (AM) has advanced considerably over recent decades through the development of novel methods, materials, and systems. As the field approaches a level of maturity, it is relevant to investigate emerging trends which may shed light on the fundamental scaling limits of AM systems to pattern matter from digital data. Here we propose a simplified mathematical model which describes process dynamics of many AM hardware platforms. In this model, the influence of several key parameters on total manufacturing time is examined and compared with performance results obtained from real-world AM systems. The model describes the dependence of volumetric build rate of many types of AM systemson their minimal feature size, and total build volume. Furthermore, we put forward a new framework for classifying manufacturing processes as “top-down” or “bottom-up,” which differs from the conventional usage of such terms. Finally, we offer a geometric model for one type of “bottom-up” manufacturing, and the limitations of such systems are contrasted with the limiting factors for “top-down” manufacturing systems.

Impact of process parameters on improving the performance of 3D printed recycled polylactic acid (rPLA) components

The main goal of this research was to investigate the influence of additive manufacturing (AM) printing parameters on the mechanical properties and surface roughness of specimens fabricated using recycled polylactic acid (rPLA). In order to achieve this goal, significant printing parameters such as layer thickness, infill density, and nozzle temperature were selected based on prior research. A three-level L9 orthogonal array, based on the Taguchi method, was used in the experimental design. The mechanical properties of virgin PLA and recycled PLA printed specimens were examined and compared. To facilitate the analysis of variance (ANOVA) examination, the response data for mechanical and surface roughness parameters were transformed to signal-to-noise (S/N) ratios. The inspected responses under consideration were the surface roughness, shore D hardness, tensile strength, flexural strength, and impact strength. The main findings suggest that careful consideration of the layer height is crucial for achieving optimum mechanical properties in the recycled PLA specimens. Furthermore, the nozzle temperature also played an important factor that affected the mechanical and surface roughness properties of the 3D printed PLA specimens. Microscopic investigation demonstrated that the number and size of voids increased significantly when the layer thickness and temperature were low, namely, 0.1 mm and 195 ℃, respectively. Finally, the optimal combination of printing parameters for each performance characteristic was determined. Following this, a confirmation test was performed using the preferred combination of parameters, which indicated a strong correlation with the outcomes predicted statistically. The results obtained from this study revealed that recycled PLA exhibited mechanical properties comparable to that of virgin PLA under certain conditions. In summary, the results of this study will serve as a valuable dataset in the field of additive manufacturing, providing valuable insights for other researchers working with recycled PLA material.

Ironing process optimization for enhanced properties in material extrusion technology using Box–Behnken Design

Material Extrusion (MEX) technology, a prominent process in the field of additive manufacturing (AM), has witnessed significant growth in recent years. The continuous quest for enhanced material properties and refined surface quality has led to the exploration of post-processing techniques. In this study, we delve into the ironing process as a vital processing step, focusing on the optimization of its parameters through the application of Design of Experiments (DoE), specifically the Box–Behnken Design (BBD). Through a systematic examination of ironing process parameters, we identified optimal conditions that resulted in a substantial reduction in surface roughness (Ra) by approximately 69%. Moreover, the integration of optimized ironing process parameters led to remarkable improvements in mechanical properties. For instance, the Ultimate Tensile Strength (UTS) saw a substantial improvement of approximately 29%, while the compressive strength (CS) showed an increase of about 25%. The flexural strength (FS) witnessed a notable enhancement of around 35%, and the impact strength (IS) experienced a significant boost of about 162%. The introduction of ironing minimizes voids, enhances layer bonding, and reduces surface irregularities, resulting in components that not only exhibit exceptional mechanical performance but also possess refined aesthetics. This research sheds light on the transformative potential of precision experimentation, post-processing techniques, and statistical methodologies in advancing Material Extrusion technology. The findings offer practical implications for industries requiring high-performance components with structural integrity and aesthetic appeal.

SAMSax—An Innovative Living Lab for the Advancement of a Circular Economy through Additive Manufacturing Technologies

The sustainable development of products is of great interest to both industry and consumers due to various factors, such as anthropogenic climate change and the scarcity of resources and materials. In response to this, the simul+ Living Lab Sustainable Additive Manufacturing in Saxony (SAMSax) has been established as a physical experimental space aimed at improving the sustainability of products. This includes selecting resource-efficient manufacturing processes, using renewable materials, reducing energy consumption during use, and designing for recyclability. The innovative approach of the lab also integrates an open innovation process, involving present and potential stakeholders. Collaborating closely with stakeholders from industry, academia, and government fosters idea generation, provides solution approaches, and enhances acceptance and practical implementation. Methodologically, SAMSax focuses on upcycling organic and inorganic residues as well as by-products from industry and agriculture, reintegrating them as innovative components in industrial production using additive manufacturing (“3D printing”). The Living Lab provides a space for networking and active knowledge transfer through digital technologies, analyses, and collaborative developments, enabling the testing and evaluation of innovations in a real-world environment. Several potential waste materials suitable for additive manufacturing and new products have already been identified. In addition to industrial residues, materials, such as paper and wood dust; industrial by-products, such as sand; and agricultural residues, like harvest residues, are being analyzed, processed, and tested using additive manufacturing in the laboratory. In this way, SAMSax can contribute to an integrated and consistent circular economy. The research aims to demonstrate that the SAMSax Living Lab is a crucial driver of innovation in the field of additive manufacturing. Furthermore, this study contributes by presenting the Living Lab as an application-oriented research environment, focusing on innovative implementation in small- and medium-sized enterprises.

Transforming Object Design and Creation: Biomaterials and Contemporary Manufacturing Leading the Way.

In the field of three-dimensional object design and fabrication, this paper explores the transformative potential at the intersection of biomaterials, biopolymers, and additive manufacturing. Drawing inspiration from the intricate designs found in the natural world, this study contributes to the evolving landscape of manufacturing and design paradigms. Biomimicry, rooted in emulating nature's sophisticated solutions, serves as the foundational framework for developing materials endowed with remarkable characteristics, including adaptability, responsiveness, and self-transformation. These advanced engineered biomimetic materials, featuring attributes such as shape memory and self-healing properties, undergo rigorous synthesis and characterization procedures, with the overarching goal of seamless integration into the field of additive manufacturing. The resulting synergy between advanced manufacturing techniques and nature-inspired materials promises to revolutionize the production of objects capable of dynamic responses to environmental stimuli. Extending beyond the confines of laboratory experimentation, these self-transforming objects hold significant potential across diverse industries, showcasing innovative applications with profound implications for object design and fabrication. Through the reduction of waste generation, minimization of energy consumption, and the reduction of environmental footprint, the integration of biomaterials, biopolymers, and additive manufacturing signifies a pivotal step towards fostering ecologically conscious design and manufacturing practices. Within this context, inanimate three-dimensional objects will possess the ability to transcend their static nature and emerge as dynamic entities capable of evolution, self-repair, and adaptive responses in harmony with their surroundings. The confluence of biomimicry and additive manufacturing techniques establishes a seminal precedent for a profound reconfiguration of contemporary approaches to design, manufacturing, and ecological stewardship, thereby decisively shaping a more resilient and innovative global milieu.

Advancements in machine learning for material design and process optimization in the field of additive manufacturing

Advancements in machine learning for material design and process optimization in the field of additive manufacturing

EcoPrintAnalyzer: Assessing Sustainability in Material Extrusion Additive Manufacturing for Informed Decision-Making

Sustainability is fundamental in the field of additive manufacturing (AM) for improving eco-consciousness and driving evolution toward environmentally responsible production methods. Compared to traditional manufacturing processes, AM technologies can be more resource-efficient and offer innovative solutions for creating eco-friendly processes and products. Nevertheless, there is significant potential for improvement in additive manufacturing sustainability. The key factors driving this improvement include design optimization and increased awareness. Designers and engineers can create designs that optimize material efficiency and reduce support structures. Raising awareness and educating stakeholders about the environmental benefits of AM can promote responsible choices throughout the industrial process. The development of a tool to assess the environmental impact of AM processes could be a significant contribution to advancing sustainability in the AM field. The EcoPrintAnalyzer, introduced as a complementary plugin for UltiMaker Cura, offers data on the equivalent carbon dioxide footprint and energy consumption in material extrusion additive manufacturing. This tool facilitates informed decision-making regarding materials, designs, and settings, enabling users to optimize their AM processes for reduced waste and enhanced energy efficiency. Beyond aiding decision-making, the EcoPrintAnalyzer fosters environmental consciousness and encourages the adoption of sustainable practices within the AM ecosystem. The efficacy of the tool is demonstrated through the 3DBenchy model case study, showcasing its intuitive interface and seamless integration within the AM process workflow for immediate and comparative environmental impact assessments across different process configurations.

MECHANICALLY EVOLUTIVE 3D-PRINTED SCAFFOLDS FOR BONE REGENERATION

Developments in the field of additive manufacturing have allowed significant improvements in the design and production of scaffolds with biologically relevant features to treat bone defects. Unfortunately, the workflow to generate personalized scaffolds is source of inaccuracies leading to a poor fit between the implant and patients' bone defects. In addition, scaffolds are often brittle and fragile, uneasing their handling by surgeons, with significant risks of fracture during their insertion in the defect. Consequently, we developed organo-mineral cementitious scaffolds displaying evolutive mechanical properties which are currently being evaluated to treat maxillofacial bone deformities in veterinary clinics. Treatment of dog patients was approved by ethic and welfare committees (CERVO-2022-14-V). To date, 8 puppies with cleft palate/lip deformities received the following treatment. Two weeks prior surgery, CT-scan of patient's skull was performed to allow for surgical planning and scaffold designing. Organo-mineral printable pastes were formulated by mixing an inorganic cement precursor (α-Ca3(PO4)2) to a self-reticulating hydrogel (silanized hyaluronic acid) supplemented with a viscosifier (hydroxymethylpropylcellulose). Scaffolds were produced by robocasting of these pastes. Surgical interventions included the reconstruction of soft tissues, and the insertion of the scaffold soaked with autologous bone marrow. Bone formation was monitored 3 and 6 months after reconstruction, and a biopsy at 6 months was performed for more detailed analyses. Scaffolds displayed great handling properties and were inserted within bone defects without significant issue with a relevant bone edges/scaffold contact. Osteointegration of the scaffolds was observed after 3 months, and regeneration of the defect at 6 months seemed quite promising. Preliminary results have demonstrated a potential of the set-up strategy to treat cleft lip/palate deformities in real, spontaneous clinical setting. Translation of these innovative scaffolds to orthopedics is planned for a near future.

Improving intellectual property management for organizations working in the field of additive manufacturing

The article is devoted to the problems that arise for state budget organizations in the management of intellectual property objects created in the field of additive manufacturing in the Russian Federation. The possibilities of their elimination by creating changes to the existing methodological documentation are considered. The paper examines the methodological documentation of leading universities on the creation of developments in the field of additive manufacturing in this country, and offers suggestions for its improvement.

Glycerol-based sustainably sourced resin for volumetric printing.

Volumetric Additive Manufacturing (VAM) represents a revolutionary advancement in the field of Additive Manufacturing, as it allows for the creation of objects in a single, cohesive process, rather than in a layer-by-layer approach. This innovative technique offers unparalleled design freedom and significantly reduces printing times. A current limitation of VAM is the availability of suitable resins with the required photoreactive chemistry and from sustainable sources. To support the application of this technology, we have developed a sustainable resin based on polyglycerol, a bioderived (e.g., vegetable origin), colourless, and easily functionisable oligomer produced from glycerol. To transform polyglycerol-6 into an acrylate photo-printable resin we adopted a simple, one-step, and scalable synthesis route. Polyglycerol-6-acrylate fulfils all the necessary criteria for volumetric printing (transparency, photo-reactivity, viscosity) and was successfully used to print a variety of models with intricate geometries and good resolution. The waste resin was found to be reusable with minimal performance issues, improving resin utilisation and minimising waste material. Furthermore, by incorporating dopants such as poly(glycerol) adipate acrylate (PGA-A) and 10,12-pentacosadyinoic acid (PCDA), we demonstrated the ability to print objects with a diverse range of functionalities, including temperature sensing probes and a polyester excipient, highlighting the potential applications of these new resins.

Thermo-Mechanical Simulation of the Powder Bed of Polyamide 12 during the Selective Laser Sintering Process

The selective laser sintering process is considered to be a new process among the most innovative techniques in the field of additive manufacturing, to facilitate the development and the technical improvement of this process, Thermo-mechanical investigation is necessary to control the SLS process, in this paper a thermo-mechanical simulation of selective laser sintering of polyamide 12 will be presented., this thermo-mechanical simulation was made under the COMSOL Multiphysics software, using Hook's law with the equilibrium and accounting equations for the calculation of the residual stresses appearing in the sintered layer of polyamide 12, this simulation was made for the prevention of deformations appeared in the final printed parts. The calculation of von Mises stress and the calculation of the magnitude of displacement within a sintered layer of polyamide 12 was done, with the analysis of the volumetric strain and the calculation of the volume: stress tensors, principal strain directions.

Advancing Free-Form Fabrication: Industrial Robots' Role in Additive Manufacturing of Thermoplastics

This paper presents a comprehensive study on the advancements and potential of industrial robots in the field of additive manufacturing of thermoplastics. As the manufacturing industry continues to embrace Industry 4.0 and smart manufacturing principles, the integration of robotic systems has gained significant attention due to their flexibility, precision, and automation capabilities. This article explores the utilization of industrial robots in achieving free-form fabrication, particularly focusing on the additive manufacturing process for composite materials. It looks into the hardware setup, software systems configuration, and platform development that combines FDM with robotic arm technologies. It discusses the merits, limitations, and prospective uses of freeform additive manufacturing and the interoperability between traditional additive manufacturing and robotic additive manufacturing. The experimental results show that this integration is feasible and advantageous, with better process flexibility and production capacities when compared to typical FDM systems.

Unveiling the Environmental and Economic Implications of Additive Manufacturing on Inbound Transportation

This studyaims to investigate the impact of additive manufacturing (AM) on the sustainability of inbound transportation. By combining insights from existing literature and interviews with professionals in the additive manufacturing field, we present a comprehensive analysis of this subject. Drawing upon both literature review and interview perspectives, it is evident that AMsignificantly influences the sustainabledimension of transportation. A key attribute of additive manufacturing is its inherent efficiency, resulting in minimized waste generation during production. This stands in contrast to traditional manufacturing methods, which involve material reduction to achieve desired shapes. The streamlined process of additive manufacturing requires fewer raw materials, thereby reducing environmental impact. The transportability of filament powder in bulk form further contributes to these sustainability gains, reducing material volume and transportation frequency. Consequently, emissions associated with additive manufacturing-related transportation are lowered. Recycling of materials is also structured within a broader framework, deviating from the conventional model of product returns to manufacturers.Despite its potential, our empirical findings suggest that the adoption of additive manufacturing doesn't consistently lead to cost reduction compared to conventional methods. The applicability of additive manufacturing remains limited to specific product ranges. Nevertheless, cost savings can occur in the realm of inbound transportation due to factors such as reduced transportation frequency and the transport-friendly nature of raw material containers. Furthermore, the efficiency of raw material usage in additive manufacturing contributes to economic benefits. Unlike conventional manufacturing, additive processes don't require extensive raw material inventories.Economic considerations extend to the adoption of distributed manufacturing systems. While centralized systems minimize raw material transportation, they may increase transportation distance for the final products. Conversely, distributed systems increase raw material travel but decrease product transportation distance. The study underscores that while distributed manufacturing offers advantages, it impacts transportation costs.In essence, this study sheds light on the complex interplay between additive manufacturing and inbound transportation sustainability. It underscores how additive manufacturing's inherent efficiencies and material characteristics have ramifications for environmental and economic dimensions. Through a blend of theoretical insights and empirical evidence, this research contributes to the broader discourse on sustainable manufacturing practices.

Safety practices and occupational hazards of the additive manufacturing of high entropy alloys

AbstractAdditive manufacturing (AM), often known as 3D printing, is becoming more popular in contemporary sectors for product development, prototyping, and the production of complicated, precise components. This technique provides benefits such as shorter production cycles, lower tooling costs, waste reduction, simpler customization, and new distribution options. AM has been applied in automotive, aerospace, medical devices, construction, and biomedical applications. High-entropy alloys (HEAs) are gaining research interest in materials science and engineering due to their multiple principal elements and potential for numerous compositions. These alloys present fundamental issues that challenge conventional theories, models, and methods. Recent studies in HEAs address phase formation, novel properties, and structural and functional potential, making HEAs promising candidates for several applications. Layer-by-layer construction of intricate structures using high-entropy alloys requires melting metal powders with lasers or other heat sources. However, AM in high-entropy alloys poses unique safety issues. This review's ultimate goal is to raise awareness of the occupational hazards associated with additive manufacturing and provide practical solutions for safe and efficient operations. It serves as an interesting call to action for employers, workers, and regulators to prioritize safety practices in the growing field of additive manufacturing of high-entropy alloys, ultimately leading to a safer and more sustainable workplace.

Smart Design of Hip Replacement Prostheses Using Additive Manufacturing and Machine Learning Techniques

The field of additive manufacturing, particularly 3D printing, has ushered in a significant transformation in the realm of joint arthritis treatment through prosthetic surgery. This innovative technology allows for the creation of bespoke prosthetic devices that are tailored to meet the specific needs of individual patients. These devices are constructed using high-performance materials, including titanium and cobalt-chrome alloys. Nevertheless, the routine physical activities of patients, such as walking, sitting, and running, can induce wear and tear on the materials comprising these prosthetic devices, subsequently diminishing their functionality and durability. In response to this challenge, this research has endeavored to leverage novel techniques. The primary focus of this study lies in the development of an algorithm designed to optimize hip replacement procedures via the mechanical design of the prosthesis. This optimization process exploits the capabilities of machine learning algorithms, multi-body dynamics, and finite element method (FEM) simulations. The paramount innovation in this methodology is the capacity to design a prosthetic system that intricately adapts to the distinctive characteristics of each patient (weight, height, gait cycle). The primary objective of this research is to enhance the performance and longevity of prosthetic devices by improving their fatigue strength. The evaluation of load distribution on the prosthetic device, facilitated by FEM simulations, anticipates a substantial augmentation in the useful life of the prosthetic system. This research holds promise as a notable advancement in prosthetic technology, offering a more efficacious treatment option for patients suffering from joint arthritis. The aim of this research is to make meaningful contributions to the enhancement of patient quality of life and the long-term performance of prosthetic devices.