Critical Analysis of Use of 3-Matics in Medical Rapid

Prototyping

Project Report is submitted to

Visvesvaraya National Institute of Technology, Nagpur

in partial fulfilment of requirement for the

Degree of

BACHELOR OF TECHNOLOGY

In

Mechanical Engineering

Submitted by

Aatish Sakhare

Vysakh Venugopal

Koshish Koirala

Mohamed Anser Abdul Latheef

Under the guidance of

Dr. A.M. Kuthe

PROFESSOR IN MECHANICAL ENGINEERING

Department of Mechanical Engineering

Visvesvaraya National Institute of Technology
Nagpur
April 2014
 Visvesvaraya National Institute of Technology, Nagpur

2013-2014

CERTIFICATE

This is to certify that the project work entitled “Critical Analysis of use of
3-Matics in Medical Rapid Prototyping.” is a bonafide work written by
Mr. Koshish Koirala, Mr. Vysakh Venugopal, Mr. Mohamed Anser Abdul
Latheef and Mr. Aatish Sakhare in the department of Mechanical
Engineering, Visvesvaraya National Institute of Technology, Nagpur, in
partial fulfillment of the requirements for the award of the degree of
Bachelor of Technology in Mechanical Engineering.

Dr. A M Kuthe Dr. S B Thombre

Project Guide Head of Department
Department of Mechanical Department of Mechanical
Engineering Engineering
VNIT, Nagpur. VNIT, Nagpur.
 Visvesvaraya National Institute of Technology, Nagpur
2013-2014

DECLARATION

This is to declare that the project entitled “Critical Analysis of use of 3-Matics in
Medical Rapid Prototyping” is a bonafide work performed by us, the below
mentioned students. This project report is being submitted and forwarded in partial
fulfillment of the requirements for the award of the degree of Bachelor of Technology
in Mechanical Engineering from Visvesvaraya National Institute of Technology-
Nagpur.

To the best of our knowledge this project report has not been submitted to any other
institution or university.

AATISH SAKHARE BT10MEC002

VYSAKH VENUGOPAL BT10MEC092

KOSHISH KOIRALA BT10MEC098

MOHAMED ANSER ABDUL LATHEEF BT10MEC103

 ACKNOWLEDGEMENT

With immense pleasure and great respect we take this opportunity to express on deep sense of
gratitude to my project guide Dr A.M.Kuthe, Professor, Department of Mechanical
Engineering, VNIT Nagpur, for his valuable guidance, inspiration, constant encouragement
and motivation throughout the project work. Also, we would like to express gratitude for
providing Lab facility, necessary software and his motivation from the beginning to the
completion of the project.

We also express our gratitude towards Dr.S.B.Thombre, Head of Department of Mechanical

Engineering, VNIT, Nagpur for his motivation throughout the project work.

We are also indebted to Mr. Sandeep Dahake and Ayushi Mukhati of Department of
Mechanical Engineering, VNIT, Nagpur for their constant guidance and help in software
study.

We are also grateful to our parents, friends, and colleagues who directly or indirectly help at
every stage to complete this work.

AATISH SAKHARE

VYSAKH VENUGOPAL

KOSHISH KOIRALA

MOHAMED ANSER ABDUL LATHEEF

4
 CONTENTS

LIST OF FIGURES……………………………………………………………8

LIST OF IMAGES……………………………………………………………..9

ABSTRACT……………………………………………………………………11

1. Introduction................................................................................................13

2. Literature Survey…………………………………………………………14

3. 3D Data Processing……………………………………………………….18

3.1. Medical Scanning……………………………………………………...18

3.2. CT Scanning................………………………………………………..18.

3.2.1. The CT Process…………………………………………………..19

3.2.2. Advantages and Disadvantages of CT Scanning………………...21

5
 3.3. MRI Scanning………………………………………………………….21

3.3.1. MRI Process…………………………………………………….22

3.3.2. Advantages and Disadvantages of MRI………………………...23

3.4. Ultrasound.....................…………………………………………… 23

3.4.1. Ultrasound Process…………………………………………… 24

3.4.2. Advantages and Disadvantages of Ultrasound………………. 24

3.5. Digital Imaging and Communications in Medicine (DICOM)…… 25

3.5.1. DICOM Process………………………………………………. 25

4. 3D Model from CTScan.……………………………………………… 27

4.1. Mimics.............…………………………………………………… 27

4.2. The Different Views………………………………………………. 28

4.3. CT Gray scale........……………………………………………… 30

4.4. 3D model Femur ……………………………………………….. 31

4.5. Steps in generating 3D model from CT Scan. …….………. 31

4.5.1. Opening the project…………………………………………… 31

4.5.2. Thresholding………………………………………………….. 33

6
 4.5.3. Region growing or Masking…………………………………… 35

4.5.4. Creating a 3D representation…………………………………. 37

4.5.5. Displaying a 3D representation……………………………… 39

5. 3-Matics………………………………………………………………… 42

5.1. What is STL? ……………………………………………………….. 42

5.2. Why choose 3-Matics………………………………………………… 44

5.3. Operations performed in 3-Matics……………………………………. 45

6. Problems with 3D Model………………………………………………. 51

6.1. Problem faced while importing STL file to ANSYS……………… 51

6.2. Problem faced in Geomagic……………………………………….. 52

7. Equivalent model analyzed in ANSYS……………………………… 53

8. Conclusion……………………………………………………………. 90

9. References …………………………………………………………….. 91

7
 LIST OF FIGURES

PAGE NO.

1.1 Figure 3.1 The workings of CT scanning 19

1.2 Figure 3.2 3D CT scan of a mandible bone 20

1.3 Figure 3.3 The working principle of an MRI Scanner 22

1.4 Figure 3.4 2D image of the knee taken by MRI machine 23

1.5 Figure 3.5 A standard DICOM Network 26

1.6 Figure 4.1 Four dimensional views details in mimics 29

1.7 Figure 4.3 Hounsfield sale 30

8
 LIST OF IMAGES PAGE NO

1) figure 4.4 femur CT opened in mimics 32

2) figure 4.5 rendered portion of DICOM image 33

3) figure 4.6 thresholding 35

4) figure 4.7 region growing or masking 36

5) figure 4.8 3d calculation 38

6) figure 4.9 model of femur 38

7) figure 4.10 3d representation of femur 40

8) figure 4.11 exporting femur to 3-matic 41

9) 5.3.1 creating new sketch on bone 45

10) 5.3.2 plate outline in sketcher view 45

11) 5.3.3 projected curve on bone 46

12) 5.3.4 part separated and saved as separate object 46

13) 5.3.5 moving surface to the required thickness 47

14) 5.3.6 importing screw 47

15) 5.3.7 Boolean sub for making screw hole 48

16) 5.3.8 final plate 48

17) 5.3.9 implant on femur 49

9
18) 5.3.10 importing to stl file in 3-matics 49

19) 5.3.11 importing stl file to mimics 50

20) 5.3.12 imported implant in mimics 50

21) equivalent elastic strain 53

22) maximum shear stress 53

23) total deformation 54

24) von misses stress 54

25) directional deformation (x-axis) 55

26) directional deformation (y-axis) 55

27) directional deformation (z-axis) 56

10
 ABSTRACT

The mechanical stress determination in human femur bone is of great

importance in both research and clinical practice. One of the methods
to estimate stress is through finite element modelling. In spite of that,
the modelling technique has to be validated by an experimental
approach as it is the best tool to access the accuracy of finite element
model predictions. However in the previous studies, this validation
has not been carried out extensively due to limited number of studies
available and the difficulties of the experiment procedure. The aim of
this project is to develop an experimental method in order to
determine the maximum stresses at the surface of the bone prototype
under normal loading. An experiment is conducted where load is
applied at the femoral head and the maximum stress on the bone
surface is determined with the presence of strain gauges.
An accurate 3D model of femur bone is prepared using Mimics and
Geomagic software. Two kinds of forces are acting on proximal end
of the femur while all degrees of freedom are fixes at distal end of
femur. Two biomaterial Ti6A14V and CoCrMo are assigned to
implants for the analysis of femur bone with implants. In this way
Finite Element Method was used extensively to study the behaviour
of femur.
With Prostheses human can live a normal life with capability to fulfil
all his/her requirements. In this study, everything is based on CT-scan
data, the whole analysis will be tailor made for the person intended.
Also patient or a victim can go for an implantation by selecting a
material having higher yield strength and longer durability. Also it
11
will give an exposure of finite element analysis and analysis software
to medical fields.

CHAPTER 1

INTRODUCTION

This project investigates the suitability of using RP technology and associated

medical software solutions to transfer 2D Digital Imaging and Communications
12
in Medicine (DICOM) data into 3d Standard Triangle Language (STL) data.
This data is then utilized using medical software solutions to manufacture
preoperative planning models and customized medical implants for the benefit
of patients and surgical planning teams alike. The project also gives an
overview of relevant subject matter such as medical scanning, RP, preoperative
planning models, customized implants/jigs and biocompatible materials. Case
studies are included as a method of illustrating how the different technologies
integrate and function to produce tangible successful outcomes that make a
significant difference in medical interventions.

Prior to RP the production of medical models of individual patients was very

rare due to the difficulty and cost of generating (usually by CNC machining)
complex geometry associated with anatomy. Medical implants were
manufactured using pressing, forging, machining and casting processes.
Unfortunately, due to the limitations of the manufacturing processes this often
resulted in bulky, poorly fitting and costly implants. With the introduction of RP
technology, these types of problems were solved using the additive
manufacturing (AM) or "layer by layer" process. Building intricate geometrical
parts suddenly became less problematic and cheaper this helped RP technology
gain acceptance by the medical profession.

CHAPTER 2

LITERRATURE SURVEY

2.1 Production of Anatomical Models from CT Scan Data by JOHN

BRENAN

13
In this project the latest medical data processing software tools will be used to
generate models for preoperative planning and also medical training and the
results reviewed. A comprehensive literature review in the field has been
conducted and publications in the medical scanning, RP, preoperative planning,
biomaterials, customized medical implants and jigs are presented and discussed.
Several case studies that are particularly pertinent to the trials undertaken by the
author have been identified and incorporated into the report and explained in
detail in order to illustrate the capability, potential and flexibility of this
technology within the medical sector.

2.2 Determination of muscle forces acting on the femur and stress

analysis by Silke Renner, Technische Universität München

A stress analysis of the femur using the finite element software ANSYS was
performed, comparing the biomechanical Pauwels’ model and the
“Stemmkörpermodel” in the one-legged stance.

2.3 Teaching Biomedical Engineering Design Process and Development

Tools to Manufacturing Students

This study presents laboratory development efforts for a rapid prototyping and
reverse engineering course taught in this ABET accredited manufacturing
engineering program. The main objective of the work is to introduce biomedical
design and development processes and associated tools in this manufacturing
program. The driving factor is to improve the versatility of the manufacturing
engineering students in addition to better marketability of the graduates in this
medically oriented geographic region and beyond. The author has been

14
developing physical and software laboratories for his biomedical engineering
program. The developed laboratories are to be utilized in the design and
manufacturing of biomedical devices and systems course and also included
within the scope of the rapid prototyping and reverse engineering course.

2.4 Design and Development of an Offset Lightweight Polymeric

Orthotic Knee Joint for Polio and Cerebral Palsy Patients BY
J.K.CHAKRABORTHY

Polio patients mostly belongs to the poor class of the society and need cheap,
light, high functioning orthotic calipers to be able to participate normally in
daily functions of life. The concept of drop lock, gravity lock or automatic lock
for calipers joint is not a very new subject as it was designed and even
commercialized in the past. This design and development work claims priority
to the prior caliper joints due to its unique design for injection molding that can
allow changes in function, material, weight and cost. The joint is designed,
analyzed, manufactured and trial tested with satisfactory results.

2.5 Nano-Materials for Bone Implants BY Garrett Cavanaugh

An increase of geriatric patients requires improved orthopedic implant

technology. Hydroxyapatite is a material naturally found in bone tissue, but the
use of synthesized hydroxyapatite in orthopedic implants is limited because of
its poor mechanical properties. The goal of this project is to use nanocrystalline

15
hydroxyapatite and epoxy resin to create composite materials that mimic bone
tissue’s nano-structure, test their mechanical properties to determine the
influence of nanostructure and characterize the failure mechanisms using
electron microscopy.

2.6 A CT-Based High-Order Finite Element Analysis of the Human

Proximal Femur BY CHARLES MILGROM

The prediction of patient-specific proximal femur mechanical response to

various load conditions is of major clinical importance in orthopaedics. This
paper presents a novel, empirically validated high-order finite element method
(FEM) for simulating the bone response to loads. A model of the bone geometry
was constructed from a quantitative computerized tomography (QCT) scan
using smooth surfaces for both the cortical and trabecular regions.
Inhomogeneous isotropic elastic properties were assigned to the finite element
model using distinct continuous spatial fields for each region. The Young’s
modulus was represented as a continuous function computed by a least mean
squares method. P-FEMs were used to bind the simulation numerical error and
to quantify the modeling assumptions. We validated the FE results with in-vitro
experiments on a fresh-frozen femur loaded by a quasi-static force of up to 1500
N at four different angles. We mea- sured the vertical displacement and strains
at various locations and investigated the sensitivity of the simulation. Good
agreement was found for the displacements, and a fair agreement found in the
measured strain in some of the locations. The presented study is a first step
toward a reliable p-FEM simulation of human femurs based on QCT data for
clinical computer aided decision making.

16
 CHAPTER 3

3D DATA PROCESSING

3.1 Medical Scanning

Medical Imaging generates a representation of a patient’s anatomy in order to

17
facilitate medical diagnosis. Techniques include Computerized Tomography
(CT), Magnetic Resonance Imaging (MRI) and Ultrasound. These tools increase
diagnostic accuracy hence reducing both risk and the recovery time of the
patient. Specific technologies are outlined below.

3.2 CT Scanning

A CT scan, also known as CAT (Computer Axial Tomography) is a non-

invasive medical scanning technique. It uses x-ray technology to obtain
geometric data of a body from different positions. A CT scan uses modified x-
ray technology, selectively exposing sections of the patient to radiation. The
data is then processed to generate a cross-section of the human body’s tissues
and organs [2]. In order to facilitate the tomography of certain organs, x-ray
opaque material may be ingested or injected. Radiologists interpret tomographs,
identifying trauma, diseases and determining the existence and impact of
various pathologies.

Figure 3.1 the working of CT scanning.

18
3.2.1 The CT Process

The X-ray tube emits a conic beam of electromagnetic radiation that selectively
penetrates the part of the body being examined; the attenuated radiation is then
encoded by a 2D detector and sent to the processing equipment as a digital
radiograph image. The body is positioned and a precision rotational stage device
0
rotates. An image is generated one step at a time at intervals between 0.25 and
0 0
1 . This produces 360 to 1440 images and covers a scan of 360 .

3D CT is a method that employs conventional 2D CT data to recreate an image

that can be viewed in all three planes. Viewing these images in three different
orientations throughout the body provides greater flexibility than conventional
planar X-rays more importantly a 3D reconstruction can be generated which
provides precise anatomical features. This is due to recent developments in 2D
CT equipment and CAD software. The development of 3D CT data is primarily
intended to simulate real life anatomical parts and is currently been used in
areas such as trauma, tumors and craniofacial deformities. 3D rendering is also
possible which lends to high quality 3D CT images.

3.2.2 Advantages and Disadvantages of CT Scanning

Advantages:

1. The process is non-invasive and accurate

2. CT scanning can produce high quality images of bone, blood vessels and soft
tissue

19
3. The examination and diagnosis of CT scans are fast and facilitate short
response times

4. More tolerant to patient movement than MRI

5. Tolerant to in vivo medical devices

6. Accurate imagery often obviates exploratory surgery

Disadvantages:

1. Radiation exposure

2. Inadvisable on pregnant women

3. Mothers breast feeding should wait 24 hours before resuming

4. Potential allergic reaction to the iodine contrast material

5. Potential imunocompromisation of children

20
 Figure 3.2 3D CT scan of a mandible bone.

3.3 MRI Scanning

In 1993 the first functional MRI machine was developed which displayed an
image of the brain .The MRI scanning technique generates pulsed radio
frequency (RF) EMR via magnetic coils. The realignment time of displaced
hydrogen atoms contained in the tissues is determined and processed to produce
an image of the tissue.

21
 Figure 3.3 The working principle of an MRI Scanner.

3.3.1 MRI Process

1. A magnetic field aligns the hydrogen protons in the body


2. RF waves are absorbed by the protons and then emitted as a signal

3. A RF coil picks up the signal and transmits it to the computer

4. The computer processes the data and generates an image

Figure 3.4 2D image of the knee taken by MRI machine.

22
3.3.2 Advantages and Disadvantages of MRI :

Advantage:-
1. MRI scans produce clear images of parts of the body that are
encapsulated by bone tissue such as the brain and spinal chord
2. Its accurate imaging and ability to differentiate tissues facilitates
diagnoses.
3. There is no exposure to electromagnetic radiation
4. Facilitates visualization of the structure of soft tissues such as cartilage

Disadvantages:

1. Intolerant of body motion

2. May induce claustrophobia

3. Intolerant of in vivo medical devices

3.4 Ultrasound

This technique uses the analysis of sound waves reflected within the human
body to generate an image. In 1962 Joseph Holmes designed the first contact B-
mode scanner.

3.4.1 Ultrasound Process

The ultrasound device emits ultrasonic sound waves when in contact with the
body. These waves, partially reflected at anatomical interfaces, are received by
a microphone in the device. The amplitude, frequency and interference profile
23
of the reflected waves is a function of the anatomy under study. This profile is
processed and displayed as an image. An interface gel may be used to enhance
sound transmission.

3.4.2 Advantages and Disadvantages of Ultrasound:

Advantages:

1. Is a non invasive procedure

2. Easy to use
3. No exposure to radiation
4. Used extensively in gynecology

Disadvantages:

1. Cannot detect all abnormalities

2. Some scans can appear abnormal and cause confusion
3. Many melanomas cannot be detected by ultrasound

3.5 Digital Imaging and Communications in Medicine (DICOM)

DICOM is a worldwide information technology standard established in 1993.

The standard covers file format and transfer protocol, permitting exchange of
data regardless of hardware origin. Devices that make up a DICOM system are:

a) Hardware modules, such as CT and MRI scanners

b) Picture Archiving and Communication Systems (PACS)

c) Reporting and post processing workstations

d) Printing services

3.5.1 DICOM Process

24
5 A CT scan is performed

6 The scanner console generates a set of images from the unprocessed data.

7 The CT console forwards the study to a PACS

8 Data is reformatted; this creates images from the original study.

9 These images are returned to the archive and merged with the rest of the
study

Figure 3.5 A standard DICOM Network.

25
 CHAPTER 4

3D MODEL FROM CT SCAN

4 .1 Mimics

Mimics interfaces between scanner data (CT, MRI, Technical scanner,...) and
Rapid Prototyping, STL file format, CAD and Finite Element analysis. The
Mimics software is an image-processing package with 3D visualization
functions that interfaces with all common scanner formats.

Additional modules provide the interface towards Rapid Prototyping using STL
or direct layer formats with support. Alternatively, an interface to CAD (design
of custom made prosthesis and new product lines based on image data) or to
Finite Element meshes is available.

Materialize' Interactive Medical Image Control System (MIMICS) is an

interactive tool for the visualization and segmentation of CT images as well as
MRI images and 3D rendering of objects. Therefore, in the medical field
Mimics can be used for diagnostic, operation planning or rehearsal purposes. A

26
very flexible interface to rapid prototyping systems is included for building
distinctive segmentation objects.

The software enables the user to control and correct the segmentation of CT-
scans and MRI- scans. For instance, image artifacts coming from metal implants
can easily be removed. The object(s) to be visualized and/or produced can be
defined exactly by medical staff. No technical knowledge is needed for creating
on screen 3D visualizations of medical objects (a cranium, pelvis, etc.)

Separate software is available to define and calculate the necessary data to build
the medical object(s) created within Mimics on all rapid prototyping systems.

The interface created to process the images provides several segmentation and
visualization tools.

Use Mimics to:

 Easily and quickly create accurate 3D models from imaging data.

 Accurately measure in 2D and 3D
 Export 3D models in STL format for additive manufacturing
 Export 3D models to 3-matic to optimize the mesh for FEA or
CFD
 And much more…

Main Features:

Import DICOM, JPEG, TIFF, BMP, or Raw image data

4.2 The Different Views

27
In the default configuration the images appear in a four-dimensional
engineering view. The images in the top right view are called the axial images
(XY-view or Top-view) and are surrounded by a red border. The upper left view
(surrounded by an orange border) shows the coronal images that are the images
resliced in the XZ-direction (Front-view). The lower left view (surrounded by a
green border) shows the sagittal images that are the images resliced in the YZ-
direction (Side-view). The lower right view (surrounded by a light-green
border) shows the 3D view.

These windows can be resized by moving the edge between the images (Click
and drag to move this edge).

Figure 4.1 Four dimensional views details in mimics

IMAGES COLOUR

28
axial red

sagittal green

coronal orange

3d view Light green

Table 4.2 four dimensional views details in mimics

4.3 CT Gray scale

CT images are a pixel map of the linear X-ray attenuation coefficient of tissue.
The pixel values are scaled so that the linear X-ray attenuation coefficient of air
equals -1024 and that of water equals 0. This scale is called the Hounsfield scale
after Godfrey Hounsfield, one of the pioneers in computerized tomography.
Using this scale, fat is around -110, muscle is around 40, trabecular bone is in
the range of 100 to 300 and cortical bone extends above trabecular bone to
about 2000.

29
 Figure 4.3 Hounsfield sale

The pixel values are shown graphically by a set of gray levels that vary linearly
from black to white. Mimics displays the CT images using up to 256 gray levels
if your display setting is true color (24-bit or 32-bit), 128 gray levels if your
display setting is 256 color palette, but as few as 32 gray levels if your display
setting is high color (16-bit). The mapping of pixel values into gray levels is
specified by a level and a width. A gray scale is centered about its level.

For example, a level of 0 specifies that water will be displayed as mid-gray. The
extent of the gray scale is specified by its width. The default gray scale used by
Mimics allows you to see the full range of tissue from air in the maxillary sinus
to the densest of cortical bone, but subtle differences in the soft tissue cannot be
visualized. If you narrow the gray scale, you can better visualize subtle
differences in the soft tissue or trabecular bone, but at the cost of forcing
cortical bone to be in one gray level: white. Narrowing the gray scale can help
you locate the mandibular canal if it is not easily seen with the default gray
scale.

4.4 3D MODEL OF FEMUR

30
For making 3d model of femur bone, we have collected the CT scan images of
femur bone available in the sample files folder in MIMICS software.

4.5 Steps in generating 3D model from CT scan

1) Opening the project

From the File menu, select Open (Ctrl+O). The Open dialog box shows all
projects in the working directory. Double click on the Mimics file (Mimics

project file).
 All images are loaded and displayed in three views. The view on

the right shows the images as they are exported by the scanner (xy-view or axial
view). The upper left corner is a reslice of these images in the xz-direction (xz-
view or coronal view) and the bottom left is a reslice in the yz-direction (yz-
view or sagittal view). The different colors of the intersecting lines refer to the
colors of the contour lines of each view so every line refers to the slice in the
corresponding view. You can easily navigate through the images by clicking on
any point of the CT images in any view: the intersecting lines will move
crossing each other in the point you clicked and all the views will be updated
showing the corresponding slices.

If you need to change the orientation of a view, go to File > Change Orientation.
This will open a window in which you can change the orientation parameters
simply by clicking on it with the right mouse button.

31
Figure 4.4 Femur CT opened in MIMICS

32
 Figure 4.5 Rendered portion of DICOM image

2) Thresholding

Thresholding means that the segmentation object (visualized by a colored mask)

will contain only those pixels of the image with a value higher than or equal to
the threshold value. Sometimes an upper and lower threshold is needed; the
segmentation mask contains all pixels between these two values.

For example:

A low threshold value makes it possible to select the Soft tissue of the scanned
patient. With a high threshold, only the very dense parts remain selected. Using
both an upper and a lower threshold is needed when the nerve channel needs to
be selected. Defining a good threshold value also depends on the purpose of the
model. If you just want a nice looking model, a lower threshold value is
33
recommended since it will result in a model with fewer holes. On the other
hand, when the model serves for modeling prostheses a higher threshold value
is preferred.

 Click the Threshold button :

To change the threshold value, press the left mouse button on a slider in the
Threshold

Toolbar and move the slider by moving the mouse (while still holding the left
mouse button). Some tips for selecting an adequate threshold value:

 Look at different images. You can change images of any view by

using the arrow keys, the page up and page down keys

 Using the slider on the right in the window border moving the slice
indicators

 Click the Profile button :

In the axial view draw a line over the bone as shown below. To draw this line,
click the left mouse button in the soft tissue to indicate the starting point, move
the mouse over the bone click. Along this line an intensity profile is generated.
The straight horizontal lines represent your current threshold value. Click on
Start Thresholding and drag the lower straight-line up/down to set a good
threshold. If you want a good visualization model, select a threshold slightly
above the intensity plateau of the soft tissue. If your model will serve for
modeling prostheses, place the line between the soft tissue plateau and the top
value of the bone. If a proper threshold is set, click on End Thresholding to
save the current value.

34
 Figure 4.6 Thresholding

3) Region growing or masking

The region growing tool makes it possible to split the segmentation created by
thresholding into several objects and to remove floating pixels.

Click the Region growing button or press Ctrl + R. The mouse is now cross-

shaped and the Region Growing window is on the screen.
 Select the Source (=

Green) and Target mask (= New Mask). Click the left mouse button on one
point in the green area of the object of interest (which is a part of the current
segmentation object, i.e. part of the skull). The program starts to calculate the
new segmentation, all points in the current segmentation object that are
connected to the marked point will be used to form a new mask. The new
segmentation is colored yellow.

 Click the Close button to close the Region growing window.

 To make this new mask active, select "Yellow" in the Visualization

35
 toolbar. Clicking on the green glasses will hide the green mask. Clicking
the button again will make the green mask visible.

 Check the mask on different images. When we check the images, we see
that everything looks fine. It’s time to build a 3D representation.

Figure 4.7 Region growing or masking

4) Creating a 3D representation

In the mask tab you see all created masks listed with their respective threshold.

36
The names of these masks are Green and Yellow. Selecting one mask will make

it active.
 Now, you still know that the Yellow mask contains the skull, but

after a month, when you reload a project, it might be difficult to know in which
mask your end result was stored. Therefore, it may be interesting to rename the
mask (in Project Management, Masks tab). Click on the name Yellow so that it
becomes editable; replace Yellow with a more telling name like „skull‟.

Click on the Calculate 3D button .


 The Calculate 3D Models Dialog box is displayed. Here you can select
from which masks you want to calculate the 3D model.

 To select multiple masks hold the Ctrl key while selecting the other
masks. In this case select “femur” and press the Calculate button to
generate a 3D object.

 You can set the visualization quality of your model. This is only the
visualization on the screen; this parameter doesn’t need to have any
impact on the model that you will actually build on an RP machine!!! Of
course, the lower the quality, the less time the program needs to calculate
the 3D image and the less memory is needed to load the 3D image
afterwards.

37
Figure 4.8 3D Calculation

Figure 4.9 Model of Femur

38
 5) Displaying a 3D representation

 In the vertical 3D toolbar on the right, you can set the visibility of the
different calculated 3Ds. This can also be done in the Project
Management's 3D Objects Tab, by clicking on the glasses.

 Once the 3D image is loaded, different operations are available:

 rotate the model with the button on the right of the 3D window or
moving the mouse pressing the right button;

 select different standard views, like Top, Front, Bottom, by clicking on

the button on the right of the window;

 zoom with the buttons or Pan with the ;

 change the color of your model and background by clicking the right
mouse button and selecting the option “Color”;

 The model can also be displayed transparent. To do so, push the Toggle

Transparency button . You can switch between different degrees of

transparency (high-medium-low- opaque) by clicking the square button

in the transparency column of the 3D objects tab.

39
Figure 4.10 3D representation of Femur

40
 6) Exporting Femur to 3-matic

The 3D model of the Femur which was created earlier was exported to 3-matic
software in which various operations for designing the implant was performed.

Figure 4.11 Exporting Femur to 3-matic

41
 CHAPTER 5

3-MATICS

3-matic is truly unique software because it is able to combine CAD tools with
pre-processing capabilities. To do this, it works on triangulated (STL) files and
as such, it is extremely suitable for organic/freeform 3D data such as the
anatomical data resulting from the segmentation of medical images (from
Mimics)

5.1 What is STL?

 STL (Stereo Lithography) is a file format native to the stereo

lithography software created by 3D systems.

 This file format is supported by many other software packages; it is

widely used for rapid prototyping and computer aided design.

 STL files describe only the surface geometry of a three dimensional

object without any representation of color, texture or other common CAD
model attributes.

3-maticSTL

Make Design Modifications Directly on STL, Scanned and CAD Data. 3-matic
offers design modification, design simplification, 3D texturing, re -meshing,
forward engineering, and much more, all on an STL level.

42
With 3-matic you can:

 Prepare your data for a quick and efficient finite element analysis;
 Design or repair missing or badly scanned components;
 Efficiently create textures, perforations and patterns on your STL data.
 Design impressive lightweight structures without compromising on
strength
 Efficiently change design so that it can be tested in wind tunnel
 And much more…

Use 3-matic to:

 Perform 3D measurements and engineering analysis.

 Design patient-specific implants or surgical guides.
 Prepare anatomical data and/or implants for Finite Element simulations.

Main Features:

 Copy/paste anatomical data from Mimics

 Import any CAD file
 Reverse engineering to IGES (Initial Graphic Exchange Specification)
 Export to all major FEA/CFD packages in the right format.
 Capturing difference between CAD data and manufactured part,
improving the analysis’ accuracy.
 Analysis of internal structures

43
5.2 Why choose 3-matics?

 3-matic provides you with a shortcut to FEA, CFD and virtual

prototyping, particularly when you’re dealing with scanned data or CAD
data originating from multiple sources.

 Save weeks by working directly on scanned data

 Instead of spending the majority of your project time on geometry

preparation, you can now focus on the actual simulation process because,
3-matic enables you to:

 Get to the optimal design faster

 Increase efficiency in the geometry preparation

 3-matic provides you with a direct link between scanned data

and FEA. Projects that previously were impractical because of
geometry complexity or the time they would consume are now
feasible.

 Analysis on physical objects for which no CAD data is

available.

44
5.3 Operations performed in 3-matic
5.3.1 CREATING NEW SKETCH ON BONE

5.3.2 PLATE OUTLINE IN SKETCHER VIEW

45
5.3.3 PROJECTED CURVE ON BONE

5.3.4 PART SEPARATED AND SAVED AS SEPARATE OBJECT

46
5.3.5 MOVING SURFACE TO THE REQUIRED THICKNESS

5.3.6 IMPORTING SCREW

47
5.3.7 BOOLEAN SUBTRACTION FOR MAKING SCREW HOLE IN
BONE AND PLATE

5.3.8 FINAL PLATE

48
5.3.9 IMPLANT ON FEMUR

5.3.10 IMPORTING TO STL FILE IN 3-MATICS

49
5.3.11 IMPORTING STL FILE TO MIMICS

5.3.12 IMPORTED IMPLANT IN MIMICS

50
 CHAPTER 6

PROBLEMS WITH 3D MODEL

A stl file generated by mimics and 3-matics based on the masked information
contains a large number of triangles with various sizes and shapes. For the finite
element analysis, the mesh will be based on the stl-file triangles, which need to
be of equal size and shape. The conversion of stl-file into a CAD-file format can
become a cumbersome task because of the uneven triangular mesh. Also we
cannot go for analysis of the 3D femur bone model obtained from Mimics
software and implant obtained from 3-matics because of some factors-

1. There were a lot of edges which are very close to each other.
2. Because of gaps and holes, femur geometry is not closed.
3. Irregular geometry means not a smooth geometry
4. Distorted patches and artefacts are there.

6.1 PROBLEM FACED WHILE IMPORTING STL FILE TO ANSYS

In order to convert the stl-file to CAD file the following softwares were tried,
viz.,

1. GEOMAGIC
2. SOILD EDGE
3. CREO 2.0

51
6.2 PROBLEMS FACED IN GEOMAGIC (TRIALVERSION)
1. All the stl files of femur and implant were converted into point clouds in
geomagic. Using the point clouds, we were able to remove the unnecessary
points manually.
2. After completing the point cloud processing we moved to thee WRAP
function of GEOMAGIC CONTROL. It is simply a click up button. It
converts point cloud into surface and volumetric polygon models with wrap
triangulation. It creates a workable polygon mesh from the point cloud.
3. While using the WRAP command, although the point cloud of femur bone
got wrapped, the wrapped portion was not proper containing lots of holes.
Fill holes command was not able to fill the holes in the femur.
4. The wrap command was not able to wrap the plate.

Because of this problem an equivalent model of bone and plate was created in
Creo 2.0 and their analysis was carried in ANSYS

52
 CHAPTER-7

EQUIVALENT MODEL ANALYZED IN ANSYS

EQUIVALENT ELASTIC STRAIN

MAXIMUM SHEAR STRESS

53
TOTAL DEFORMATION

VON MISSSES STRESS

54
DIRECTIONAL DEFORMATION (X-AXIS)

DIRECTIONAL DEFORMATION (Y-AXIS)

55
DIRECTIONAL DEFORMATION (Z-AXIS)

56
PROJECT REPORT GENERATED IN ANSYS

First Saved Friday, April 18, 2014

Last Saved Friday, April 18, 2014

Product Version 14.0 Release

Save Project Before Solution No

Save Project After Solution No

Units

TABLE 1

57
 Unit System Metric (mm, t, N, s, mV, mA) Degrees rad/s Celsius

Angle Degrees

Rotational Velocity rad/s

Temperature Celsius

Model (A4)

Geometry

TABLE 2
Model (A4) > Geometry

Object Name Geometry

State Fully Defined

Definition

C:\Users\HP\Desktop\screenshots of
Source
ansys\finalprojectansys_files\dp0\SYS\DM\SYS.agdb

Type DesignModeler

Length Unit Millimeters

Element Control Program Controlled

Display Style Body Color

Bounding Box

Length X 28.245 mm

Length Y 480. mm

58
 Length Z 31.4 mm

Properties

Volume 2.2709e+005 mm³

Mass 4.8819e-004 t

Scale Factor
1.
Value

Statistics

Bodies 9

Active Bodies 9

Nodes 8158

Elements 2893

Mesh Metric None

Basic Geometry Options

Parameters Yes

Parameter Key DS

Attributes No

Named
No
Selections

Material
No
Properties

Advanced Geometry Options

Use
Yes
Associativity

Coordinate No

59
 Systems

Reader Mode
Saves Updated No
File

Use Instances Yes

Smart CAD
No
Update

Attach File Via

Yes
Temp File

Attach File Via Temp File Yes

Temporary Directory C:\Users\HP\AppData\Roaming\Ansys\v140

Analysis Type 3-D

Decompose Disjoint Faces Yes

Enclosure and Symmetry

Yes
Processing

TABLE 3
Model (A4) > Geometry > Parts

Object Name Solid Solid Solid Solid Solid

State Meshed

Graphics Properties

Visible Yes

Transparency 1

Definition

60
 Suppressed No

Stiffness
Flexible
Behavior

Coordinate
Default Coordinate System
System

Reference
By Environment
Temperature

Material

Titanium
Assignment bone material bone material Structural Steel
Alloy NL

Nonlinear
Yes
Effects

Thermal Strain
Yes
Effects

Bounding Box

28.245
Length X 23.4 mm 23.4 mm 10. mm
mm

9.8869
Length Y 240. mm 150. mm 240. mm 9.899 mm
mm

10.385
Length Z 23.4 mm 23.4 mm 18. mm
mm

Properties

1.0129e+005 21995 1.0129e+005

Volume 418.26 mm³
mm³ mm³ mm³

1.0162e-
Mass 1.8344e-004 t 1.8344e-004 t 3.2833e-006 t
004 t

61
 Centroid X 11.7 mm

-2.204e-
Centroid Y 118.98 mm -118.98 mm -65. mm -45. mm
004 mm

-9.66e-003 0.22603 0.22672

Centroid Z -11.747 mm -11.747 mm
mm mm mm

Moment of 0.85942 0.18682 0.85942 1.0926e- 1.0924e-

Inertia Ip1 t·mm² t·mm² t·mm² 004 t·mm² 004 t·mm²

Moment of 1.2381e-002 7.1798e- 1.2381e-002 1.0998e- 1.0997e-

Inertia Ip2 t·mm² 003 t·mm² t·mm² 004 t·mm² 004 t·mm²

Moment of 0.85948 0.19271 0.85948 1.5271e- 1.5268e-

Inertia Ip3 t·mm² t·mm² t·mm² 005 t·mm² 005 t·mm²

Statistics

Nodes 1155 3396 1225 387 408

Elements 600 585 653 170 186

Mesh Metric None

TABLE 4
Model (A4) > Geometry > Parts

Object Name Solid Solid Solid Solid

State Meshed

Graphics Properties

Visible Yes

Transparency 1

Definition

Suppressed No

62
 Stiffness Behavior Flexible

Coordinate System Default Coordinate System

Reference Temperature By Environment

Material

Assignment Structural Steel

Nonlinear Effects Yes

Thermal Strain Effects Yes

Bounding Box

Length X 10. mm

Length Y 9.8869 mm

Length Z 18. mm

Properties

Volume 418.26 mm³

Mass 3.2833e-006 t

Centroid X 11.7 mm

Centroid Y -20. mm 20. mm 45. mm 65. mm

Centroid Z 0.22672 mm 0.22671 mm

Moment of Inertia Ip1 1.0924e-004 t·mm²

Moment of Inertia Ip2 1.0997e-004 t·mm²

Moment of Inertia Ip3 1.5268e-005 t·mm²

Statistics

Nodes 400 393 400 394

63
 Elements 177 172 177 173

Mesh Metric None

Coordinate Systems

TABLE 5
Model (A4) > Coordinate Systems > Coordinate System

Object Name Global Coordinate System

State Fully Defined

Definition

Type Cartesian

Coordinate System ID 0.

Origin

Origin X 0. mm

Origin Y 0. mm

Origin Z 0. mm

Directional Vectors

X Axis Data [ 1. 0. 0. ]

Y Axis Data [ 0. 1. 0. ]

Z Axis Data [ 0. 0. 1. ]

Connections

TABLE 6
Model (A4) > Connections

Object Name Connections

64
 State Fully Defined

Auto Detection

Generate Automatic Connection On Refresh Yes

Transparency

Enabled Yes

TABLE 7
Model (A4) > Connections > Contacts

Object Name Contacts

State Fully Defined

Definition

Connection Type Contact

Scope

Scoping Method Geometry Selection

Geometry All Bodies

Auto Detection

Tolerance Type Slider

Tolerance Slider 0.

Tolerance Value 1.2046 mm

Use Range No

Face/Face Yes

Face/Edge No

Edge/Edge No

65
 Priority Include All

Group By Bodies

Search Across Bodies

TABLE 8
Model (A4) > Connections > Contacts > Contact Regions

Bonded - Bonded -
Contact Contact Contact
Object Name Solid To Solid To
Region Region 4 Region 5
Solid Solid

State Fully Defined

Scope

Scoping
Geometry Selection
Method

Contact 1 Face 3 Faces

Target 6 Faces 1 Face 3 Faces

Contact
Solid
Bodies

Target Bodies Solid

Definition

Type Bonded

Scope Mode Automatic Manual Automatic

Behavior Program Controlled

Suppressed No

Advanced

Formulation Program Controlled

66
 Detection
Program Controlled
Method

Normal
Program Controlled
Stiffness

Update
Program Controlled
Stiffness

Pinball
Program Controlled
Region

TABLE 9
Model (A4) > Connections > Contacts > Contact Regions

Contact Contact Contact Contact Contact

Object Name
Region 6 Region 7 Region 8 Region 9 Region 10

State Fully Defined

Scope

Scoping
Geometry Selection
Method

Contact 6 Faces 2 Faces

Target 1 Face 2 Faces

Contact
Solid
Bodies

Target Bodies Solid

Definition

Type Bonded

Scope Mode Automatic

Behavior Program Controlled

67
 Suppressed No

Advanced

Formulation Program Controlled

Detection
Program Controlled
Method

Normal
Program Controlled
Stiffness

Update
Program Controlled
Stiffness

Pinball
Program Controlled
Region

TABLE 10
Model (A4) > Connections > Contacts > Contact Regions

Contact Contact Contact Contact Contact

Object Name
Region 11 Region 12 Region 13 Region 14 Region 15

State Fully Defined

Scope

Scoping
Geometry Selection
Method

Contact 2 Faces 3 Faces

Target 2 Faces 3 Faces

Contact
Solid
Bodies

Target Bodies Solid

Definition

68
 Type Bonded

Scope Mode Automatic

Behavior Program Controlled

Suppressed No

Advanced

Formulation Program Controlled

Detection
Program Controlled
Method

Normal
Program Controlled
Stiffness

Update
Program Controlled
Stiffness

Pinball
Program Controlled
Region

Mesh

TABLE 11
Model (A4) > Mesh

Object Name Mesh

State Solved

Defaults

Physics Preference Mechanical

Relevance 0

Sizing

Use Advanced Size Function Off

69
 Relevance Center Coarse

Element Size Default

Initial Size Seed Active Assembly

Smoothing Medium

Transition Fast

Span Angle Center Coarse

Minimum Edge Length 1.23420 mm

Inflation

Use Automatic Inflation None

Inflation Option Smooth Transition

Transition Ratio 0.272

Maximum Layers 5

Growth Rate 1.2

Inflation Algorithm Pre

View Advanced Options No

Patch Conforming Options

Triangle Surface Mesher Program Controlled

Advanced

Shape Checking Standard Mechanical

Element Midside Nodes Program Controlled

Straight Sided Elements No

Number of Retries Default (4)

70
 Extra Retries For Assembly Yes

Rigid Body Behavior Dimensionally Reduced

Mesh Morphing Disabled

Defeaturing

Pinch Tolerance Please Define

Generate Pinch on Refresh No

Automatic Mesh Based Defeaturing On

Defeaturing Tolerance Default

Statistics

Nodes 8158

Elements 2893

Mesh Metric None

Static Structural (A5)

TABLE 12
Model (A4) > Analysis

Object Name Static Structural (A5)

State Solved

Definition

Physics Type Structural

Analysis Type Static Structural

71
 Solver Target Mechanical APDL

Options

Environment Temperature 22. °C

Generate Input Only No

TABLE 13
Model (A4) > Static Structural (A5) > Analysis Settings

Object Name Analysis Settings

State Fully Defined

Step Controls

Number Of Steps 1.

Current Step
1.
Number

Step End Time 1. s

Auto Time
Program Controlled
Stepping

Solver Controls

Solver Type Program Controlled

Weak Springs Program Controlled

Large Deflection Off

Inertia Relief Off

Restart Controls

Generate Restart
Program Controlled
Points

72
 Retain Files After
No
Full Solve

Nonlinear Controls

Force Convergence Program Controlled

Moment
Program Controlled
Convergence

Displacement
Program Controlled
Convergence

Rotation
Program Controlled
Convergence

Line Search Program Controlled

Stabilization Off

Output Controls

Stress Yes

Strain Yes

Nodal Forces No

Contact
No
Miscellaneous

General
No
Miscellaneous

Calculate Results
All Time Points
At

Max Number of
Program Controlled
Result Sets

Analysis Data Management

Solver Files C:\Users\HP\Desktop\screenshots of

73
 Directory ansys\finalprojectansys_files\dp0\SYS\MECH\

Future Analysis None

Scratch Solver
Files Directory

Save MAPDL db No

Delete Unneeded
Yes
Files

Nonlinear Solution Yes

Solver Units Active System

Solver Unit System nmm

TABLE 14
Model (A4) > Static Structural (A5) > Loads

Object Name Force Fixed Support

State Fully Defined

Scope

Scoping Method Geometry Selection

Geometry 1 Face

Definition

Type Force Fixed Support

Define By Vector

Magnitude 167. N (ramped)

Direction Defined

Suppressed No

74
 FIGURE 1
Model (A4) > Static Structural (A5) > Force

Solution (A6)

TABLE 15
Model (A4) > Static Structural (A5) > Solution

Object Name Solution (A6)

State Solved

Adaptive Mesh Refinement

Max Refinement Loops 1.

75
 Refinement Depth 2.

Information

Status Done

TABLE 16
Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information

Object Name Solution Information

State Solved

Solution Information

Solution Output Solver Output

Newton-Raphson Residuals 0

Update Interval 2.5 s

Display Points All

FE Connection Visibility

Activate Visibility Yes

Display All FE Connectors

Draw Connections Attached To All Nodes

Line Color Connection Type

Visible on Results No

Line Thickness Single

Display Type Lines

TABLE 17
Model (A4) > Static Structural (A5) > Solution (A6) > Results

76
 Maximum Equivalent Vector
Object Total Directional
Shear Elastic Principal
Name Deformation Deformation
Stress Strain 2 Stress

State Solved

Scope

Scoping
Geometry Selection
Method

Geometry All Bodies

Definition

Maximum Equivalent Vector

Total Directional
Type Shear Elastic Principal
Deformation Deformation
Stress Strain Stress

By Time

Display
Last
Time

Calculate
Time Yes
History

Identifier

Suppressed No

Orientation Y Axis

Global
Coordinate
Coordinate
System
System

Results

Minimum 0. mm -3.4824e-002 1.2568e- 1.0885e-008

77
 mm 003 MPa mm/mm

3.4975e-002 17.223 1.5479e-003

Maximum 0.93669 mm
mm MPa mm/mm

Minimum
Solid
Occurs On

Maximum
Solid
Occurs On

Minimum Value Over Time

-3.4824e-002 2.5178e- 2.1805e-009

Minimum 0. mm
mm 004 MPa mm/mm

-6.9649e-003 1.2568e- 1.0885e-008

Maximum 0. mm
mm 003 MPa mm/mm

Maximum Value Over Time

6.995e-003 3.4447 3.0958e-004

Minimum 0.18734 mm
mm MPa mm/mm

3.4975e-002 17.223 1.5479e-003

Maximum 0.93669 mm
mm MPa mm/mm

Information

Time 1. s

Load Step 1

Substep 4

Iteration
7
Number

Integration Point Results

Display
Averaged
Option

78
 FIGURE 2
Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation

TABLE 18
Model (A4) > Static Structural (A5) > Solution (A6) > Total Deformation

Time [s] Minimum [mm] Maximum [mm]

0.2 0.18734

0.4 0.37468
0.
0.7 0.65568

1. 0.93669

FIGURE 3
Model (A4) > Static Structural (A5) > Solution (A6) > Directional
Deformation

79
 TABLE 19
Model (A4) > Static Structural (A5) > Solution (A6) > Directional
Deformation

Time [s] Minimum [mm] Maximum [mm]

0.2 -6.9649e-003 6.995e-003

0.4 -1.393e-002 1.399e-002

0.7 -2.4377e-002 2.4483e-002

1. -3.4824e-002 3.4975e-002

FIGURE 4
Model (A4) > Static Structural (A5) > Solution (A6) > Maximum Shear
Stress

80
 TABLE 20
Model (A4) > Static Structural (A5) > Solution (A6) > Maximum Shear
Stress

Time [s] Minimum [MPa] Maximum [MPa]

0.2 2.5178e-004 3.4447

0.4 5.0326e-004 6.8894

0.7 8.8023e-004 12.056

1. 1.2568e-003 17.223

81
 FIGURE 5
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Elastic
Strain 2

TABLE 21
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Elastic
Strain 2

Time [s] Minimum [mm/mm] Maximum [mm/mm]

0.2 2.1805e-009 3.0958e-004

82
 0.4 4.3586e-009 6.1917e-004

0.7 7.6234e-009 1.0835e-003

1. 1.0885e-008 1.5479e-003

TABLE 22
Model (A4) > Static Structural (A5) > Solution (A6) > Results

Object Name Equivalent Stress

State Solved

Scope

Scoping Method Geometry Selection

Geometry All Bodies

Definition

Type Equivalent (von-Mises) Stress

By Time

Display Time Last

Calculate Time History Yes

Identifier

Suppressed No

Integration Point Results

Display Option Averaged

Results

Minimum 2.177e-003 MPa

Maximum 32.513 MPa

83
 Minimum Occurs On Solid

Maximum Occurs On Solid

Minimum Value Over Time

Minimum 4.3611e-004 MPa

Maximum 2.177e-003 MPa

Maximum Value Over Time

Minimum 6.5027 MPa

Maximum 32.513 MPa

Information

Time 1. s

Load Step 1

Substep 4

Iteration Number 7

FIGURE 6
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress

84
 TABLE 23
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress

Time [s] Minimum [MPa] Maximum [MPa]

0.2 4.3611e-004 6.5027

0.4 8.7171e-004 13.005

0.7 1.5247e-003 22.759

1. 2.177e-003 32.513

Material Data

Bone material

85
 TABLE 24
bone material > Constants

Density 1.811e-009 tonne mm^-3

Specific Heat 7.8e+008 mJtonne^-1 C^-1

Thermal Conductivity 7.2e-004 W mm^-1 C^-1

TABLE 25
bone material > Compressive Yield Strength

Compressive Yield Strength MPa

200

TABLE 26
bone material > Tensile Yield Strength

Tensile Yield Strength MPa

100

TABLE 27
bone material > Isotropic Elasticity

Temperature Young's Modulus Poisson's Bulk Modulus Shear Modulus

C MPa Ratio MPa MPa

30000 0.18 15625 12712

Titanium Alloy NL

TABLE 28
Titanium Alloy NL > Constants

86
 Density 4.62e-009 tonne mm^-3

Specific Heat 5.22e+008 mJtonne^-1 C^-1

TABLE 29
Titanium Alloy NL > Isotropic Elasticity

Temperature Young's Poisson's Bulk Modulus Shear Modulus

C Modulus MPa Ratio MPa MPa

96000 0.36 1.1429e+005 35294

TABLE 30
Titanium Alloy NL > Bilinear Isotropic Hardening

Yield Strength MPa Tangent Modulus MPa Temperature C

930 2150

Structural Steel

TABLE 31
Structural Steel > Constants

Density 7.85e-009 tonne mm^-3

Coefficient of Thermal Expansion 1.2e-005 C^-1

Specific Heat 4.34e+008 mJtonne^-1 C^-1

Thermal Conductivity 6.05e-002 W mm^-1 C^-1

Resistivity 1.7e-004 ohm mm

TABLE 32
Structural Steel > Compressive Ultimate Strength
87
 Compressive Ultimate Strength MPa

TABLE 33
Structural Steel > Compressive Yield Strength

Compressive Yield Strength MPa

250

TABLE 34
Structural Steel > Tensile Yield Strength

Tensile Yield Strength MPa

250

TABLE 35
Structural Steel > Tensile Ultimate Strength

Tensile Ultimate Strength MPa

460

TABLE 36
Structural Steel > Isotropic Secant Coefficient of Thermal Expansion

Reference Temperature C

22

TABLE 37
Structural Steel > Alternating Stress Mean Stress

Alternating Stress MPa Cycles Mean Stress MPa

3999 10 0

88
 2827 20 0

1896 50 0

1413 100 0

1069 200 0

441 2000 0

262 10000 0

214 20000 0

138 1.e+005 0

114 2.e+005 0

86.2 1.e+006 0

TABLE 38
Structural Steel > Strain-Life Parameters

Cyclic
Strength Cyclic Strain
Strength Ductility Ductility Strength
Coefficient Hardening
Exponent Coefficient Exponent Coefficient
MPa Exponent
MPa

920 -0.106 0.213 -0.47 1000 0.2

TABLE 39
Structural Steel > Isotropic Elasticity

Temperature Young's Poisson's Bulk Modulus Shear Modulus

C Modulus MPa Ratio MPa MPa

2.e+005 0.3 1.6667e+005 76923

89
 CONCLUSION

For generating 3D model various techniques are available but most appropriate
are CT scan method because CT scan gives us exact profile of geometry. Hence
by generating accurate 3D model of femur bone of patient, diagnostics can be
carried out especially for that patient more conveniently. Hence, doctors can see
bone model from different view and at different angle because full details can’t
be gathered from CT scan data.

Titanium alloys had best mechanical and physical properties for material used
in development of bio medical implants. It is a super strong, light weight
material. Also the stresses induced are well within the limiting values. The only
problem with titanium alloy is the cost.

Finite element method thus makes the stress analysis of complex 3D object
simple and more easily understandable which helps in medical field for analysis
of bone under loading conditions. It is expected that extensive use of finite
element method for analysis of femur using different implant materials and
structural arrangements will help in development of new biomedical implant.

As everything is based on CT scan data, the whole analysis will be tailor made
for the person intended. So this is just a footstep forward to improve the quality
of life of a patient.

90
 REFERENCE

1. 3-matics reference guide.pdf

2. 3-matics tutorial.pdf

3. Nano materials for bone implants by Worcester Polytechnic Institute.

4. Development and Verification of a Computational Model of the Knee

Joint for the Evaluation of Surgical Treatments for Osteoarthritis by R.
Mootanah.

5. A CT-Based High-Order Finite Element Analysis of the Human Proximal

Femur Compared to In-vitro Experiments by Charles Milgrom
(Department of Orthopaedics, Hadassah University Hospital, Jerusalem
91120, Israel).

6. 3-matic assists in True Rapid Design
and Manufacturing of a Custom

Skull Implant by Ing. M.M.A. Beerens, Ing. P. Laeven, Drs. J. Poukens.

7. Indian Journal of Biomechanics by Subrata Pal

(Founder Director, School of Bioscience & Engineering, Jadavpur
University, Kolkata, India).

8. Mimics reference guide.pdf

9. Mimics tutorials.pdf

10. Production of Anatomical Models from CT Data by John Brenan.

91