Abstract
A new approach for the production of cranial implants using CNC-controlled two point incremental sheet forming (TPIF) is presented. The use of titanium sheets for implant manufacturing offers the possibility for production of relatively thin parts involving a lower amount of scrap compared to machining. For this purpose a forming process is required which is suitable for economical production of individualized parts with an adequate accuracy. TPIF is a process suitable for prototyping and small batch production due to the minor tooling effort and high flexibility compared to traditional sheet forming processes. Furthermore, incremental sheet forming allows the processing of pure titanium sheets suitable for medical applications.
In the present paper, a production chain is introduced which includes TPIF, heat treatment and cutting of the part. The manufacturing steps were developed and optimized with respect to the requirements for cranial implants. The possibility to use different initial semi-finished products solid titanium sheets and expanded metals will be described and discussed.
Experiments will be evaluated to show the applicability of TPIF for cranial implant production. The produced implants will be compared to the CAD-geometry, and their accuracy will be determined. It will be shown, that a maximum deviation of the implants edge compared to the CAD-geometry is less than 2mm. Finally an outlook will show possible approaches for further optimization of the process.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Eufinger, H.; Wehmöller, M.; Harders, A.; Heuser, L. (1995): Prefabricated prostheses for the reconstruction of skull defects, in: Oral and Maxillofacial Surgery 24, 104–110.
Wehmöller, M., Eufinger, H. (2000): Das TICC-Verfahren (Tomography Imageprocessing CAD CAM) zur individuellen Implantatherstellung, in: Biomedizinische Technik 45, Ergänzungsband 1, 402–403
Eufinger, H.; Rasche, C.; Wehmöller, M.; Schmieder, K.; Scholz, M.; Weihe, S.; Scherer, P. (2005): CAD-CAM titanium implants for cranioplasty – an evaluation of success and quality of life of 169 consecutive im-plants with regard to size and location, in: International Congress Series 1281, 827–831.
Wehmöller, M.; Eufinger, H.; Kruse, D.; Maßberg, W. (1995): CAD by processing of computed tomography data and CAM of individually de-signed prostheses, in: Oral and Maxillofacial Surgery 24, 90–97.
Meier, H., Eufinger, H., Wehmöller, M. (2004): A New Embedding Clamping Device with Low Melting Alloy, Production Engineering, XI/1, 81–84.
Jeswiet, J.; Micari, F.; Hirt, G.; Bramley, A.; Duflou, J.; Allwood, J. (2005): Asymmetric Single Point Incremental Forming of Sheet Metal, in: Annals of the CIRP 54, 623–649.
Ames, J. (2008): Systematische Untersuchung der Beeinflussung des Werkstoffflusses bei der Inkrementellen Blechumformung mit CNC-Werkzeugmaschinen, Dissertation, Institut für Bildsame Formgebung, RWTH Aachen.
Duflou, J.R.; Lauwers, B.; Verbert, J.; Tunckol, Y.; De Baerdemaeker, H. (2005): Achievable Accuracy in Single Point Incremental Forming: Case Studies, in: Proceedings of the 8th ESAFROM Conference on Material Forming, 675–679.
Duflou, J.R.; Verbert, J.; Tunckol, Y.; Gelaude, F.; Lauwers, B. (2005): Customised Medical Implant Production by Means of Single Point Incremental Forming, in: Proceedings of the 2th International Conference on Manufacturing Engineering (ICMEN), 217–225.
Ames, J.; Hirt, G.; Ziegler, S. (2007): Neue Ansätze in der inkrementellen Blechumformung (IBU): Erweiterung des Anwendungsspektrums durch Verfahrenskombination, in: Tagungsbans zum 22. Aachener Stahlkolloquium.
Junk, S. (2003): Inkrementelle Blechumformung mit CNC-Werkzeugmaschinen: Verfahrensgrenzen und Umformstrategien. Schriftenreihe Produktionstechnik, Band 25, Dissertation. Saarbrücken.
GOM mbH (Gesellschaft für Optische Messtechnik) (2008): ATOS Benutzerhandbuch – Software, Braunschweig.
Ames, J.; Bambach, M.; Hirt, G. (2005): A new forming strategy to realise parts designed for deep-drawing, in Steel Research int. 76, No. 2/3, 160–166
ASM Handbook, Volume 14: Forming and Forging (1996), Semiatin, S.L. (Chairman), 1835–1869.
Duflou, J.R.; Callebaut, B.; Verbert, J.; De Baerdemaeker, H. (2007): Laser Assisted Incremental Forming: Formability and Accuracy Improvement, in: CIRP Annals – Manufacturing Technology 56 (1), 273–276.
Biermann, T.; Göttmann, A.; Zettler, J.; Bambach, M.; Weisheit, A.; Hirt, G.; Poprawe, R. (2009): Hybrid Laser-Assisted Incremental Sheet Forming – Improving Formability of Ti- and Mg-Based Alloys, in: Proceedings of the Fifth International WLT-Conference on Lasers in Manufacturing, München.
Göttmann, A.; Diettrich, J.; Bergweiler, G.; Bambach, M.; HIRT, G.; Loosen, P.; Poprawe, R. (2011): “Laser-assisted asymmetric incremental sheet forming of titanium sheet metal parts”. Production Engineering, 1–9, ISSN 0944–6524. URL: http://dx.doi.org/10.1007/s11740-011-0299-9
Taleb Araghi, B.; Göttmann, A.; Bergweiler, G.; Saeed-Akbari, A.; Bültmann, J.; Zettler, J.; Bambach,M.; Hirt, G. (2011) : Investigation on Incremental Sheet Forming Combined with Laser Heating and Stretch Forming for the Production of Lightweight Structures, in: Key Engineering Materials Vol. 473, 919–928, Trans Tech Publications, Switzerland, doi:www.scientific.net/KEM.473.919
Acknowledgements
The authors would like to thank the “Exploratory Research Space @ RWTH Aachen” ERS for supporting this work and the German Research Foundation DFG for the support within the Cluster of Excellence “Integrative Production Technology for High-Wage Countries”.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2013 Springer-Verlag Berlin Heidelberg
About this paper
Cite this paper
Göttmann, A., Korinth, M., Schäfer, V., Araghi, B.T., Bambach, M., Hirt, G. (2013). Manufacturing of Individualized Cranial Implants Using Two Point Incremental Sheet Metal Forming. In: Schuh, G., Neugebauer, R., Uhlmann, E. (eds) Future Trends in Production Engineering. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-24491-9_28
Download citation
DOI: https://doi.org/10.1007/978-3-642-24491-9_28
Published:
Publisher Name: Springer, Berlin, Heidelberg
Print ISBN: 978-3-642-24490-2
Online ISBN: 978-3-642-24491-9
eBook Packages: EngineeringEngineering (R0)