Numerical simulation and additive manufacturing technology in design of knee implant patterns

Abstract

The paper presents the possibilities to apply Numerical Simulation and Additive Manufacturing (AM) technology in designing the prototypes of master patterns of knee implants for investment casting. The master pattern manufacturing by wax injection is the starting operation in the investment casting procedure. Errors caused by shrinkage, air traps and the lower quality of surface roughness may occur in the wax injection process. The software SolidWorks Plastics was used in this research in order to avoid these errors. The software analyzed the fill time, gate location, temperatures and pressures. The second part of the research presents the comparison of different AM processes (Selective Laser Sintering, 3D Printing and PolyJet) considering the characteristics of the material and the manufacturing time of the prototypes of knee implant patterns.