Non-planar additive manufacturing for biomedical applications

Abstract

Fused filament fabrication (FFF) stands out as a prominent technology in additive manufacturing (AM) due to its affordability and versatility in equipment and materials. Its suitability for research and development is evident. Recent advancements have led to the development of non-planar AM using FFF 3D printers, enabling the fabrication of curved structures with enhanced mechanical and aesthetic properties. This innovation has significantly reduced printing time and material waste while expanding the capabilities of FFF to print non-planar metamaterials. Notably, FFF finds practical application in the 3D printing of cranioplasty implants. This thesis investigates the utilization of non-planar AM for manufacturing such implants, focusing on dome-shaped structures for mechanical testing. Various topologies, including hexagonal, re-entrant, and squared honeycomb metamaterials, are explored for reinforcement. The study culminates in a comparative analysis between traditional planar cranioplasty implants and those manufactured with non-planar layers and lattice reinforcement, offering insights into their respective benefits and limitations.