Searching for the Least Deformation
In this case study, we used Finite Element simulation to quickly predict the global deformations of three different part-support configurations of a patient-specific cranio-maxillofacial implant. The coarse voxelization approach allowed for fast simulation and quick feedback about the qualitative deformation tendencies of the configuration. Actual test prints confirmed that out of the three proposed configurations in this study, the configuration in the middle showed the least deformation after support removal.
Therefore, this second simulation case also confirms that the predictive power of simulation is a valuable tool for AM engineers. With the use of the Magics simulation module, they can evaluate their designs prior to manufacturing, allowing them to quickly find the optimal part orientation and support configuration. Materialise is leveraging nearly 30 years of AM experience to develop AM-specific simulation approaches that will make our “AM lives” easier.
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* The Inherent Strain Method (ISM) is a simulation procedure that was adapted from welding simulation to predict residual stresses and deformations during the Additive Manufacturing (AM) process. The ISM is a simplification of the complex, time-dependent, thermo-mechanical AM process into a simple quasi-static analysis which allows for fast and accurate simulation of complex additive components.
Please note that Materialise Magics is not a medical (device) software. The user has the responsibility to validate the production process and their product for use as a medical device. Materialise's orthognathic implants are protected by patents EP 2398411, US 8,784,456, US9,247,972, US 9,339,279. Further patents pending.