APPLICATION OF HPC TOOLS FOR THE OPTIMIZATION OF 3D-PRINTED ORTHOPAEDIC DEVICES
The project incorporates HPC tools in the manufacturing process of CastPrint products to reduce printing time and material, increase mechanical strength and wearability through improved ventilation of the cast. This will be achieved by using topological optimization of the product’s geometry.
Start date: 01/06/2021
Duration in months: 18
Problem Description
Plaster of Paris (PoP) casts have been used in fracture treatment for over 150 years, however, they are time-consuming and material-intensive. CastPrint,, has been providing custom 3D printed medical devices since 2016, catering to the growing demand for patient-centric healthcare solutions.
Goals
Virtual prototyping
Challenges
3D printed casts are faster than traditional ones but time-consuming due to manual operations and millions of surface elements in 3D scans. This results in software crashes and data loss, increasing the time needed to deliver the device to the patient, despite the potential for faster production.
Innovation results
The experiment partners have integrated parametric model optimization into the design process of a 3D printed cast, using simulations to determine the most efficient shape. This reduces material requirements and shortens printing times. HPC enables faster simulations and automation.
Business impact
Cast design has seen a 20% reduction in man-hours, 25% reduction in material usage, and a 15% reduction in production costs. Topological optimization has also reduced production time and printing durations. CastPrint has increased production capacity by up to 25%, with an expected ROI of 15%-20%.