International Journal of Research In Science & Engineering
Volume: 1 Issue: 3
e-ISSN: 2394-8299
p-ISSN: 2394-8280
AN INTEGRATED APPROACH OF REVERSE ENGINEERING FOR
DIMENSIONAL & ERROR ANALYSIS OF CUSTOMIZED
HUMERUS BONE IMPLANT
Manish D. Toprakwar1, Rahul M. Sherekar2, Swapnil S. Bele3, Pankaj D. Morey4
1
Mechanical Engineering, JDIET, Yavatmal, India [email protected]
Professor, Mechanical Engineering, JDIET, Yavatmal, India [email protected]
3
Mechanical Engineering, JDIET, Yavatmal, India [email protected]
4
Mechanical Engineering, JDIET, Yavatmal, India [email protected]
_____________________________________________________________________________________
2
ABSTRACT
This research paper presents the application of reverse engineering in medical field. Over last 15 years
the production of preoperative planning model has increased dramatically and moreover. The use of this model
will helpful for surgeon to reduce risk, time of operation and increase the patient confidence and life also. The
first step in reverse engineering is CT scanning and digitization of data. The CT data obtained in DICOM format
which is subjected to processing and imported in CAD program for further customization and STL formation .
So in such cases it is necessary to evaluate the model whether it is manufactured accurately or not. As human
body has irregular structure, so it is not possible to model & manufacture accurately such a critical shape like
human bone, craniofacial implants etc. On completion of this paper it became apparent that certain RP
technologies and associated software such as Mimics and 3-matic has indeed many advantages to offer the
medical profession with regard to preoperative planning models and customized medical implants. Although not
fully accepted by all, constant research and development in RP technology, biomaterials and software solutions,
means that medical implant technology will continue to improve.
In this paper the result of dimensional & error analysis of Humerus customized implant manufactured by RP
(FDM) has been discussed by using advance optical measurement technique.
Keywords: Rapid prototyping, Reverse engineering, optical measurement technique.
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1. INTRODUCTION
RP technologies and associated software such as Materialize, Mimics and 3-matic has indeed many
advantages to offer the medical profession with regard to preoperative planning models and customized medical
implants. Although not fully accepted by all, constant research and development in RP technology, biomaterials and
software solutions, means that medical implant technology will continue to improve.
The first (and major) applications of RP in medicine and health-care are the production of (physical)
biomodels that can be used as an aiding tool for surgical planning and rehearsal. Since every patient is unique, the
surgeon must fully understand the anatomy of the patient before operation. Obtaining a full understanding of the
patient’s anatomy only by the study of a mass of CT/MRI images in these cases requires great experience from the
surgeon, especially in complex surgical operations. In such cases RP biomodels greatly facilitate diagnosis and
treatment planning, and decrease the risk of misinterpretation of the medical problem. Having a physical biomodel
in hand also facilitates surgery planning and makes possible the rehearsal and simulation of the operation through
marking, cutting and reassembling of the biomodel. Furthermore, the pre-surgical study of a biomodel allows not
only the detailed evaluation of the operation, without the time pressure present during actual operation, but also
possible problem prediction. This way, actual operation time, and consequently operation cost and
infection/anesthesia risk are decreased. Biomodels are also very useful as a communication tool between medical
IJRISE| www.ijrise.org|[email protected] [130-136]
International Journal of Research In Science & Engineering
Volume: 1 Issue: 3
e-ISSN: 2394-8299
p-ISSN: 2394-8280
personnel. They are also very useful for the presentation of operation details to people with no medical expertise
(e.g. the patient or its relatives), thus increasing consent and trust.
In most cases, RP is applied for the fabrication of customized bone models. The most widely reported
application of RP biomodelling for surgical planning is in the field of maxillo-craniofacial surgery, which involves
the surgical treatment of congenital or acquired deformations both for functional and aesthetic purposes. The
geometry of the skull is quite complex and cannot be easily reproduced in a physical model using cutting
manufacturing methods like CNC milling. RP therefore presents a reasonable alternative. Among RP technologies,
SLS is the most commonly used in craniofacial biomodelling.
Therefore it is necessary to evaluate the accuracy of anatomical impant manufactured by RP technique.
The application of Reverse Engineering (RE) in the field of medicine and dentistry is resulting in biomedical objects
or implants with adequate properties for the biomedical needs. The examples are: different types of implants
(personalized, dental, artificial hip joints), external orthopedic prostheses, bony tissue scaffolds. Another field of
application of RE in medicine includes visualization, diagnostic (diagnosis), surgery planning, surgical templates,
production of the artificial organs, training and teaching .
The objective of this paper is to present a RE process of the Humerus bone manufactured by RP. The
activities involved in our modeling approach are:
1) CT scanning,
2) Medical modeling software
3) Generation of STL file
4) Creation of a 3D surface model of Humerus bone by using RP.
5) Optical Measurement Of RP Manufactured Humerus.
6) Error detection between RP modal and cad modal
Fig-1: Flow of CT file to STL file.
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International Journal of Research In Science & Engineering
Volume: 1 Issue: 3
e-ISSN: 2394-8299
p-ISSN: 2394-8280
2. CASE STUDY
A 35 years old man had left Humerus bone completely distorted in accident & has to replace.
A mirrored model of the right side Humerus bone is built using FDM technique and can be use as a pattern
for manufacturing Humerus bone. The CT scan data of right Humerus bone was taken and was converted into .STL
file format.
During the conversion of CT scan data to the CAD file there always occurs some data losses. These data
losses are refined and CAD data is reconstructed. Above figure is to represent the CAD file after reconstruction.
CAD file gives us 3D view. As the rapid manufacturing is the additive manufacturing process, model is constructed
by layer by layer formation. The above figure is to represent the under construction images of Humerus bone. We
used the FDM (fused deposition modeling) technology to manufacture the Humerus bone model.
Fig-2: RP Manufactured modal of Humerus
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International Journal of Research In Science & Engineering
Volume: 1 Issue: 3
e-ISSN: 2394-8299
p-ISSN: 2394-8280
3. RESULT AND DISCUSSION
The dimensional and error analysis of RP manufactured medical implants i.e. Humerus is carried out by the
latest optical technologies namely Blue light Scanner. the dimensional and error analysis is done by means of
mapping the previous scanned data from which the RP model of a particular medical implant get manufactured and
the scanned data obtained from optical scanning . By mapping these two scanning data the absolute deviation is
directly obtained at a particular point.
The dimensional and error analysis of the Humerus is done by using ‘Blue Light Scanner ’and result are as follows:
Fig-3: Image of Master scan data and test scan data.
Fig-4: Overlap image of master scan data and test scan data.
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International Journal of Research In Science & Engineering
Volume: 1 Issue: 3
e-ISSN: 2394-8299
p-ISSN: 2394-8280
Fig-5: Dimensional error between master scan data and test scan data.
Fig-6: Dimensional error between master scan data and test scan data.
Name of case study
RP
manufacturing
technology
Measurement
Technique
Dimensional mean error
between CAD and RP
model
(mm)
Humerus
SLA
Blue light scanner
0.1
Table-1: Result of Dimensional and error analysis
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International Journal of Research In Science & Engineering
Volume: 1 Issue: 3
e-ISSN: 2394-8299
p-ISSN: 2394-8280
The study showed that there is dimensional error between CAD model and RP manufactured model. The
use of rapid prototyping allows rapid manufacture of accurate three-dimensional physical models. We found that
these models were very helpful in preoperative assessment, classification and preoperative planning of acetabular
fractures. The models allow the surgeon to view and handle accurate anatomical replicas .The surgeons all agreed
that the models greatly improved their understanding of the personality of these complex fractures. The models were
also useful for surgical simulation prior to surgery and education of junior trainees, medical and nursing students
and theatre staff.
Medical models have a critical role in cranio-maxillofacial surgery. The accuracy of medical model
manufacturing has not been investigated sufficiently. If the model is not accurate enough, there is the possibility of
fatal errors to occurring when these models are used for preoperative planning or surgical simulation. In addition,
implant manufacturing with the help of medical models may potentially have severe consequences as a result of
errors in the AM process. Our results demonstrate that different manufacturing methods may cause significant
errors.
None of the previous studies comment on the measurements of anatomical implant manufactured by RP.
When measuring anatomic points in the human body, it is hard to determine an exact measuring point because the
forms are usually smooth and exact points are difficult to find with commonly used measuring equipment.
The process of making medical models involves various steps, each of which can be a source of error.
Errors can occur during the imaging, segmentation or manufacturing phase. It might be possible that different errors
have been disproved by other errors in the study. Furthermore, it is hard to approve these error in medical model
which is manufactured by such a expensive and accurate technology.
4. CONCLUSION
The result obtained through dimensional and error analysis by using optical measurement technique of these
medical implants and preoperative models, we can conclude that the presented approach provides a 3D surface
model of the Humerus with high accuracy and precision. The resulting model is convenient for building of the solid
model as well as for rapid prototyping of the bone and the results is found to be good and acceptable.
Hence, the RP technology can be successfully used in the field of biomedical, which will ultimately
increase the safety level and save the life of humans
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p-ISSN: 2394-8280
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