The main idea behind this paper is to highlight efforts made to improve the application potential of the fused deposition modelling (FDM) process by producing the rapid prototyping parts at minimum cost. Build orientation analysis for prismatic, curved boundary, and complex-shaped parts is carried out. The mathematical model is formulated to estimate the total cost of part preparation in FDM. Optimal part build orientation and the values of parameters resulting in the minimum total cost of parts preparation are identified. The parts produced by the FDM rapid prototyping process are considered for build orientation analysis. The concept can be extended for parts produced with any layered manufacturing process. This is the first attempt to deal with diversified types of part geometries and formulate a universal cost model applicable for all types of parts to determine minimum cost in FDM.

Purpose -The purpose of this paper was to find a successful treatment modality for patients suffering from temporomandibular joint (TMJ) ankylosis who could not be treated through traditional surgeries. Design/methodology/approach -This work integrated the unique capabilities of the imaging technique, the rapid prototyping (RP) technology and the advanced manufacturing technique to develop the customised TMJ implant. The patient specific TMJ implant was fabricated using the computed tomography scanned data and the fused deposition modeling of RP for the TMJ surgery.Findings -This approach showed good results in fabrication of the TMJ implant. Postoperatively, the patient experienced normalcy in the jaw movements. Practical implications -Advanced technologies helped to fabricate the customised TMJ implant. The advantage of this approach is that the physical RP model assisted in designing the final metallic implant. It also helped in the surgical planning and the rehearsals. Originality/value -This case report illustrates the benefits of imaging/computer-aided design/computer-aided manufacturing/RP to develop the customised implant and serve those patients who could not be treated in the traditional way.

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The approach utilised will be helpful in providing successful treatment to the deformed mandible and the mandible joints. This method allows to customise and to accurately fabricatie the implant. Advantages of this approach are that the physical model of the implant was tested for stability before the implantation, the surgeon can plan and rehearse the surgery in advance, it is a less invasive and less time-consuming surgical procedure.

Joint replacement surgeries in India primarily involve the use of conventional implants, also referred to as 'standard implants'. There has been a little awareness about the possibility of using customised implants for such surgeries. Although standard implants from various biomedical companies are easily available in the Indian market, they are expensive and rarely conform to patient's anatomy. Studies in the past have shown that there are anatomical variations in the hip joint for different ethnic backgrounds and geographical locations. This article evaluates the feasibility of using custom-manufactured hip implants and presents a comparison between the former and standard implant from stress reduction point of view. Two CAD models of femoral stems - one from standard sized hip implant available in the market and other from customised hip implant designed as per parameters from a radiograph (specific to the patient's anatomy) - are used for evaluation. Finite element analysis was carried out for a double-legged stance. The comparative study indicated lesser stresses in head and neck region of the customised femoral stems than the standard implant. The study suggests design feasibility of customised implants for the Indian population owing to reduction in stresses in the implant.