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This paper investigates the opportunity of implementing FE simulations and rapid prototyping tecniques on titanium implant in maxillofacial surgery case based on osteotomy. Maxilla region was recorded by Cone Beam CT with high resolution and optimal radiation. Then, it followed the medical image reconstruction into 3D voxelized model. This model was converted both, to stl surface model for rapid prototyping, CAD modeling and FE mesh for simulation purposes with keeping good volume and dimensional consistency. Stl meshed surface was imported into CAD software, as initial 3d structure, which is used for parametric and customized design of implant. Since, the osteotomy is final application, it wassimulated the cutting and shifting of maxilla for proper correction by digital prototyping. Then, the fixation points for shifted maxilla were determined by surgeon to provide steady and tight joints between implanting screws and maxilla. Applied implant was given in initial standard flat configuration. Flat implant configuration was adapted by complex 3D bending in CAD software to be customized towards surface conformity of maxillofacial anatomy. By FE simulation in MSC Patran/Nastran, it was performed the stress analysis of implant with different thickness configurations and 3D bending, which provides the optimized implant model with best fit dimensions. Optimized implant model and corresponding body model were converted into physical models. RP model of maxilla was post-processed by cutting and boring to provide an adequate implant positioning according to digital prototypes. This approach facilitated the preparation of complex shaped implants in swept and lofted form, what had to be in high degree of conformity to anatomy surface. To approve a good practical opportunity, it was applied and tested in concrete surgery case of maxillofacial osteotomy.

Abstract:The application of the two technologies: reverse engineering and rapid prototyping is emerging rapidly in the medical applications. These engineering methods have especially shown fast advancement in the following applications: in very complex preparation of computer aided surgery, computer guided implantology, non-invasive diagnostic from CT and MRI scans, design of customized implants, maxillofacial surgery, esthetic and reconstructive plastic surgery, orthopedic surgery, etc. This research has a multidisciplinary approach; it requires a team work of experts from various scientific fields such as CAD design and virtual engineering, digital image processing, medicine, implantology. Only a very few applicative pioneer steps have been made so far in Republic of Srpska, Bosnia and SE Europe in general.The aim of this research is to make a contribution to the optimization of all three phases: preprocessing, processing and post-processing in the process chain of reverse engineering -rapid prototyping in the medical applications. The optimal process of rapid prototyping has been defined for different medical input data and formats. The process includes internal 3d reconstruction of CT and MRI scanning in DICOM format, such as applications in orthopedic surgery, maxillofacial surgery, prosthetic dentistry, such as complex or total prosthesis, as well as the external surface reconstruction by 3d scanning, such as esthetic surgery and reconstruction plastic surgery or dentistry based on 3d scanning from elastic silicone impression.

This paper presents the advantages and the process of making of complex functional parts using additive manufacturing technology. Design and manufacturing of components were performed at the Laboratory for Technology of Plasticity and Processing Systems at the Faculty of Mechanical Engineering in Banja Luka. The parts were designed using SolidWorks and Catia software packages. Then, CatalystEX and Simplify3D software packages were used to process the CAD model and to prepare it for 3D printing, which included defining of the process parameters, generating layers and support. Functional parts were produced on 3D printers based on the principle of material extrusion. The results of this study show that additive manufacturing technology, specifically technology based on material extrusion, enables very fast production of complex functional parts, with high accuracy and much lower costs and development time compared to conventional technologies.