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A novel framework for designing and manufacturing cranial prostheses through incremental sheet metal forming

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Abstract

This investigation aims to propose a novel framework for designing and manufacturing cranial prostheses through incremental sheet metal forming (ISF). First, the three-dimensional models of the defective crania and the prosthesis were constructed from the CT data. Then, to verify the formability of the prosthesis model, a method for testing the mesh sheet’s incremental forming limit (IFL) was proposed with a variable angle cone model. The angle between the normal vector of the fracture point and the Z-axis calculated the IFL. The tests showed that the method could realize the testing of the IFL of the mesh sheet with the reduction of processing time and cost. In addition, finite element modeling and experimental trials were used to evaluate the ISF process of the prosthesis, including thickness distribution and geometric accuracy. The results showed that the incremental forming can form prosthesis samples with high precision, while the thickness distribution is relatively uniform without excessive thinning. Finally, the obtained prosthesis sample was practically assembled with the cranial defect model to verify the fitting effect and feasibility of the prosthesis formed by the ISF process.

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Funding

The work is supported by National Natural Science Foundation of China—International (Regional) Cooperation and Exchange Program (No. 5201101342) and Jiangsu Province Science and Technology Project (No. BK20200453). Besides, this study is supported via funding from Prince Sattam Bin Abdulaziz University (Project number PSAU/2023/R/1444).

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Authors and Affiliations

  1. College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 211100, Jiangsu, China

    Shuo Zheng, Jie Tao, Xunzhong Guo, Chunmei Liu & Cheng Cheng

  2. Department of Mechanical Engineering, College of Engineering, Kharj, Prince Sattam Bin Abdulaziz University, 11942, Al Kharj, Saudi Arabia

    Ali Abd El-Aty

  3. Mechanical Engineering Department, Faculty of Engineering-Helwan, Helwan University, Cairo, Egypt

    Ali Abd El-Aty

  4. School of Materials Science and Engineering, Nanjing Institute of Technology, Nanjing, 21000, Jiangsu, China

    Guangcheng Zha

Authors
  1. Shuo Zheng
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  2. Ali Abd El-Aty
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  3. Jie Tao
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  4. Xunzhong Guo
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  5. Guangcheng Zha
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  6. Chunmei Liu
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  7. Cheng Cheng
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Contributions

All authors contributed to the study conception and design. CC, JT, and XG performed material preparation, data collection, and analysis. The experiments was performed by SZ and CL. The first draft of the manuscript was written by SZ, GZ, and AAE-A. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Cheng Cheng.

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Zheng, S., El-Aty, A.A., Tao, J. et al. A novel framework for designing and manufacturing cranial prostheses through incremental sheet metal forming. Int J Adv Manuf Technol 129, 3901–3916 (2023). https://doi.org/10.1007/s00170-023-12581-w

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  • DOI: https://doi.org/10.1007/s00170-023-12581-w

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