Design,optimization and fabrication of a 3D printing orthopedic calf cast

Tumijan, Nurfarhana (2018) Design,optimization and fabrication of a 3D printing orthopedic calf cast. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The 3D printing orthopedic calf cast was a support tool used to control and guide the fractured joint in calf until healing is confirmed by the doctor. Current design in Malaysia, plaster cast, it came up with many disadvantages to patient, like discomfort and heavy. This current technological world development in industries looking forward to come up with lightweight and user-friendly products. A project was carried out to provide the design and development of the support tool. Computer Aided Design (CAD) software and Finite Element Analysis (FEA) computer software were used to design and to optimize the product, without effect its possibility to withstand certain patient mass. By using different applied masses/loads, it will be analysed to find the best shape design. T-Scan LV system, the scanning machine that had been used for scanning process. Then, the printing process was used the Farsoon SS 402P laser sintering system. FS3200PA Nylon powder was chosen for the material of cast, as it is generally good antioxidative properties, and there are no known adverse health effects. Through optimization and analysis, three light models are proven to be a safe-to-use model. However, only one model with safety factor of 2.33 and thickness of 2mm is chosen for printing as it can withstand the highest patient weight of 981N while trying to achieve the desired mass.

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