Volvo Cars in Skövde manufacture and assemble Volvo engines. When attaching the ignition coil to all 4-cylinder engines, a special mounting tool is required. This mounting tool is currently manufactured from injection-molded polyoxymethylene (POM), a thermoplastic. It has been noted that the life span of the tool is shortened as a result of abrasive wear that occurs during the attachment process of the ignition coil. An investigation of the possibility of manufacturing the mounting tool with a 3D-printer is undertaken in cooperation with ÅF, a consultant to Volvo Cars. A literature study is first presented to introduce broader knowledge on the subject. The abrasive wear and other material characteristics such as tensile strength, compressive strength and elongation of  POM and an alternative material for 3D-printing,  Ultem™, an amorphous thermoplastic polyetherimide are discussed.  These material characteristics are studied further and considered in tandem with both a theoretical analysis and a wear experiment, based on the pin-on-disc method. It is shown in the theoretical analysis that the wear is approximately six times larger for Ultem™ when compared to POM. The wear resistance of Ultem™ is highest when wear occurs parallel to the direction of the printed layers. In contrast, the experiment shows that the wear is about three times larger in Ultem™ than in POM.  The highest tensile strength of Ultem™ is also found in the direction of the printed layers. Some issues with the small elongation of the 3D-printed material are presented. It is recommended that ÅF apply the 3D-printing technique with Ultem™ only for construction details with complex geometries and where the material elongation will not exceed 5%. It is also recommended that ÅF both support and contribute to this innovative technique in order to develop leading edge competence in the subject. / Volvo Cars i Skövde tillverkar och monterar Volvomotorer. Vid monteringen av tändspolen till alla 4-cylindriga motorer behövs ett monteringsverktyg. Detta monteringsverktyg tillverkas för närvarande från formsprutad termoplast polyoximetylen (POM). Det har noterats att livslängden av verktyget förkortas på grund av abrasiv nötning som uppkommer under monteringsprocessen av tändspolen. Möjligheterna att tillverka monteringsverktyget med en 3D-skrivare utvärderas i samverkan med ÅF, en konsult till Volvo Cars. En litteraturstudie presenteras för att introducera en bredare kunskap i ämnet. Den abrasiva nötningen och materialegenskaper såsom draghållfasthet, tryckhållfasthet samt töjning hos POM och ett alternativt material för 3D-skrivning, Ultem™, en amorf termoplast polyeterimid, behandlas. Dessa materialegenskaper studeras vidare och tas i beaktning med både en teoretisk analys och ett nötningsexperiment, baserat på pin-on-disc metoden. Enligt den teoretiska analysen är nötningen hos Ultem™ approximativt 6 gånger större vid jämförelsen med POM. Nötningsbeständigheten hos Ultem™ är högst då nötning sker parallellt med 3D-skrivningsriktningen av lagren. Nötningsexperimenten visar att nötningen hos Ultem™ är ungefär 3 gånger större vid jämförelsen med POM. Den högsta draghållfastheten hos Ultem™ uppkommer också parallellt med 3D-skrivningsriktningen av lagren. Problem med den låga töjningen hos det 3D-skrivna materialet behandlas. ÅF rekommenderas att tillämpa 3D-skrivning med materialet Ultem™ främst för detaljer med komplexa geometrier med en töjning som inte överskrider 5 %. ÅF rekommenderas även att både stödja och bidra till denna innovativa teknik för att kunna skapa en ledande expertis i ämnet.

The following report presents a Master thesis project about a re-design of an ankle foot orthosis using additive manufacturing as the production method, conducted by a student in Spring 2020 as part of the Master’s programme Industrial Design at Jönköping University’s School of Engineering. Ankle foot orthoses are the most prescribed lower extremity orthoses worldwide and are worn in a visually obtrusive way making patients feel stigmatized for their disability. The social stigma makes it emotionally difficult for many users to wear an AFO frequently enough for proper rehabilitation. Despite its significance and wide spread use, its design has not changed for over 50 years. Traditional manufacturing methods are difficult to work with and make customization options very limited. By using digital additive manufacturing methods like 3D Scanning, 3D printing and computer simulations, it is possible to offer personalized looks for AFOs by implementing almost any custom pattern expressed in cut-outs on the AFO surface. That kind of perforation simultaneously solves the problem of bad perspiration and air flow. The freedom of graphical expression in those patterns invite the patient to participate in the design process themselves to create an ankle foot orthosis that is their own. That revolutionary twist on the manufacturing and design process empowers the user to take control over their disability to the furthest degree possible and returns the human right of self-determination and independence to them. / Följande rapport presenterar ett examensarbete gällade en omdesign av en ankel-fot-ortos med additiv tillverkning som produktionsmetod, genomförd av en student våren 2020 som del av masterprogrammet Industrial Design vid Jönköpings universitets tekniska högskola. Ortoser för fotleden är de mest föreskrivna ortoserna för underkroppen i hela världen och bärs på ett visuellt påträngande sätt vilket gör att patienterna kan känna sig annorlunda eller utanför för sin funktionsnedsättning. Den sociala stigmatiseringen gör det känslomässigt svårt för många användare att bära en AFO ofta nog för korrekt rehabilitering. Trots dess betydelse och breda användning har designen inte förändrats på över 50 år. Traditionella tillverkningsmetoder är svåra att arbeta med och begränsar alternativen för anpassning. Genom att använda digitala metoder för additiv tillverkning som 3D-skanning, 3D-utskrift och datorsimuleringar är det möjligt att erbjuda ett personligt utseende för AFO genom att införa en stor mängd anpassade mönster i form av utskärningar på AFO-ytan. Denna typ av perforering löser samtidigt problemet med svett och dåligt luftflöde. Friheten för grafiskt uttryck genom dessa mönster låter patienten delta i själva designprocessen för att fotledsortosen ska kännas som deras egen. Detta nya synsätt på utveckling på tillverknings- och designprocessen gör det möjligt för användaren att ta kontroll över sin funktionsnedsättning i största möjliga grad och återställer känslan av självständighet.

The aim of this thesis is to optimize the design of the Fat-IBC-based communication of a novel neuroprosthetic system in which a brain-machine interface is used to control a prosthetic arm. Fat-based intra-body communication (Fat-IBC) uses the fat tissue inside the body of the bearer as a transmission medium for low-power microwaves. Future projects will use the communication system and investigate ways to control the prosthetic arm directly from the brain. The finished system was able to individually control all movable joints of multiple prosthesis prototypes using information that was received wirelessly through Fat-IBC. Simultaneous transmission in the other direction was possible, with the control data then being replaced by sensor readings from the prosthesis. All data packets were encoded with the COBS/R algorithm and the wireless communication was handled by Digi Xbee 3 radio modules using the IEEE 802.15.4 protocol at a frequency of 2.45 GHz. The Fat-IBC communication was evaluated with the help of so-called "phantoms" which emulated the conditions of the human body fat channel. During said testing, packet loss measurements were performed for various combinations of packet sizes and time intervals between packets. The packet loss measurements showed that the typical amount of transmitted data could be handled well by the fat channel test setup. Although the transmission system was found to be well-functioning in its current state, increasing the packet size to achieve a higher granularity of the movement was perceived to be viable considering the findings from the packet loss measurements.

The world health organization has predicted that by 2030, depression will cause more early deaths and disability than cancer, stroke, or accidents. The number of burnouts has been increasing during the past years since we are so focused on our materialistic needs, educating ourselves in managing our devices. Meanwhile, we have not learned how to manage our own emotions. In our Swedish society today, we have people from different backgrounds and linguistic skills that find it difficult to talk about their emotional states and ask for help. At the same time, most of the methods used in therapy are done verbally or in writing that can be hard, even for those who speak the same language. In my project, I have interviewed psychotherapists and individuals who have attended therapy sessions. Speaking to a therapist, I realized the lack of physical objects in this field where almost everything is communicated verbally or on paper. During my process, I have learned about the importance of three-dimensional objects for a patient and how these objects can be used as aids to help one open up and express emotions. In this area, I have explored the following question: Whether or not emotions would abstract into forms? Can we describe our mixed emotions by using shapes, objects, and colors? What can I, as a designer, contribute to the two-dimensional world of therapy and mental health? Based on the results from several workshops and studying Robert Putchik’s theory of emotions, I created a set of tools. These aiding tools help the patient to open up about mixed feelings and break them down into primary emotions. These tools aim to help the patient to address and categorize emotions and easily communicate with the therapist. / Världshälsoorganisationen har förutspått att vid 2030 kommer depression att orsaka mer tidiga död och funktionshinder än cancer, stroke eller olyckor. Antalet utbrändhet har ökat under de senaste åren eftersom vi är så fokuserade på våra materialistiska behov, lär oss att hantera tekniken men vi har inte lärt oss hur vi ska hantera våra egna känslor.   Detta är aktuell idag i det svenska samhället där folk med olika bakgrund som har språksvårigheter lyckas inte uttrycka deras känslomässiga tillstånd för att få det hjälp det behöver. Samtidigt, de flesta metoderna som används i terapi sker muntligt eller skriftligt, vilket kan vara svårt även för dem som pratar samma språk.   I mitt projekt har intervjuat psykoterapeuter och individer som har varit på terapisessioner. Under processens gång har jag insett betydelsen som ett tredimensionellt objekt kan ha för patienten och hur detta kan användas som hjälpmedel och stöd. Inom detta område har jag bearbetat följande frågor: Huruvida skulle känslor abstraheras i former? Kan vi beskriva våra blandade känslor med hjälp av objekt? Vad kan jag som designer bidra till den tvådimensionella världen av terapi och psykisk hälsa?

Three-dimensional (3D) printing has become broadly available and can be utilized to customize clamping mechanisms in biomechanical experiments. This report will describe our experience using 3D printed clamps to mount soft tissues from different anatomical regions. The feasibility and potential limitations of the technology will be discussed. Tissues were sourced in a fresh condition, including human skin, ligaments and tendons. Standardized clamps and fixtures were 3D printed and used to mount specimens. In quasi-static tensile tests combined with digital image correlation and fatigue trials we characterized the applicability of the clamping technique. Scanning electron microscopy was utilized to evaluate the specimens to assess the integrity of the extracellular matrix following the mechanical tests. 3D printed clamps showed no signs of clamping-related failure during the quasi-static tests, and intact extracellular matrix was found in the clamping area, at the transition clamping area and the central area from where the strain data was obtained. In the fatigue tests, material slippage was low, allowing for cyclic tests beyond 105 cycles. Comparison to other clamping techniques yields that 3D printed clamps ease and expedite specimen handling, are highly adaptable to specimen geometries and ideal for high-standardization and high-throughput experiments in soft tissue biomechanics.

This project was conducted as a case study at Öhlins Racing AB, a manufacturer of suspension systems for automotive applications. Öhlins usually manufacture their components by traditional methods such as forging, casting, and machining. The project aimed to investigate how applicable Additive Manufacturing (AM) is to manufacture products for suspension systems to add value to suspension system components. For this, a proof of concept was designed and manufactured. The thesis was conducted at Öhlins in Upplands Väsby via the consultant firm Combitech.  A product catalog was searched, screened, and one part was selected. The selected part was used as a benchmark when a new part was designed for AM, using methods including Topology Optimization (TO) and Design for Additive Manufacturing (DfAM). Product requirements for the chosen part were to reduce weight, add functions, or add value in other ways.  Methods used throughout the project were based on traditional product development and DfAM, and consisted of three steps: Product Screening, Concept Development, and Part Design. The re-designed part is ready to be manufactured in titanium by L-PBF at Amexci in Karlskoga.  The thesis result shows that at least one of Öhlin's components in their product portfolio is suitable to be chosen, re-designed, and manufactured by AM. It is also shown that value can be added to the product by increased performance, in this case mainly by weight reduction. The finished product is a fork bottom, designed with hollow structures, and is ready to print by L-PBF in a titanium alloy.

Additive manufacturing (AM) has enabled the possibility for the hospitals to become their own implant producers developing implants that are tailored to patient’s anatomy. Despite the enormous potential of custom-made implants there are challenges that complicate the implementation of them into clinical practice. The aim of this research is to (1) identify the main driving forces and barriers for the delivery of custom-made implants; (2) explore staff stakeholder views and practices related to the implementation of AM in surgery for the development of custom-made implants; (3) formulate recommendations on how to cope with the implementation challenges. The research method was an explorative qualitative study consisted of a literature review on the challenges of custom-made implants in clinical applications coupled with the collection and inductive analysis of empirical data. The empirical study was based on ten semi-structured interviews conducted among both domestic and international hospital managers medical doctors and research engineers. The consolidated framework for implementation research (CFIR) was utilized for data collection. Using the five domains of CFIR, the following results were obtained: (1) Characteristics of individuals: Most research participants indicated a positive attitude towards the innovation expressing self-efficacy to its use; (2) Intervention characteristics: Custom-made implants were perceived to have a relative advantage in surgical practice due to their high degree of observability and geometrical adaptability providing increased surgical quality, perfect patient fit and better understanding of pathologies. However, high implementation costs, low degree of trialability and high degree of complexity in the development process were regarded as drawbacks of the innovation; (3) Outer setting: the regulatory uncertainty and lack of reimbursement limit the accessibility of custom-made implants to low income populations; (4) Inner setting: scarcity of resources, staff resistance to change, insufficient management support, communication difficulties, limited access to educational materials and training opportunities as well as lack of time and innovative capacity were regarded by the majority of participants as implementation barriers; (5) Process: central for the success of implementation is the need for a coherent implementation plan and evaluation process as well as the engagement of key stakeholders such as hospital managers, payers, regulatory and implementation advisors. This dissertation proffers a deeper understanding of the implementation issues related to custom-made implants and offers preliminary recommendations on how to cope with implementation impediments through the use of Rogers diffusion of innovation coupled with concepts from the field of organizational change and innovation management including Clayton’s disruptive innovation.

Indiana University-Purdue University Indianapolis (IUPUI) / Instrument assisted soft tissue mobilization (IASTM) is a form of massage using rigid manufactured or cast devices. The delivered force, which is a critical parameter in massage during IASTM, has not been measured or standardized for most clinical practices. In addition to the force, the angle of treatment and frequency play an important role during IASTM. As a result, there is a strong need to characterize the delivered force to a patient, angle of treatment, and stroke frequency. This thesis proposes two novel mechatronic designs for a specific instrument from Graston Technique(Model GT3), which is a frequently used tool to clinically deliver localize pressure to the soft tissue. The first design is based on compression load cells, where 4-load cells are used to measure the force components in three-dimensional space. The second design uses a 3D load cell, which can measure all three force components force simultaneously. Both designs are implemented with IMUduino microcontroller chips which can also measure tool orientation angles and provide computed stroke frequency. Both designs, which were created using Creo CAD platform, were also analyzed thorough strength and integrity using the finite element analysis package ANSYS. Once the static analysis was completed, a dynamic model was created for the first design to simulate IASTM practice using the GT-3 tool. The deformation and stress on skin were measured after applying force with the GT-3 tool. Additionally, the relationship between skin stress and the load cell measurements has been investigated. The second design of the mechatronic IASTM tool was validated for force measurements using an electronic plate scale that provided the baseline force values to compare with the applied force values measured by the tool. The load cell measurements and the scale readings were found to be in agreement within the expected degree of accuracy. The stroke frequency was computed using the force data and determining the peaks during force application. The orientation angles were obtained from the built-in sensors in the microchip.

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Die neuen Fertigungsmöglichkeiten durch die Additive Fertigung ermöglicht es nicht nur topologisch neuartige Bauteile herzustellen, sondern auch Bauteile mit inneren Strukturen zu versehen, die der Bauteilbelastung angepasst sind oder anderen Funktionen Freiräume bieten. Ein Ansatz ist es durchlässige innere Strukturen, z. B. Gitterstrukturen (auch als Lattice Strukturen bezeichnet) einzusetzen und durch die damit geschaffenen großen inneren Flächen eine effiziente Bauteilkühlung zu realisieren. Anhand eines einfachen Beispiels wird durch Simulation und Experiment die Wirkung einer solchen Kühlung gezeigt. Als weiteres Anwendungsbeispiel wird der Einsatz verschiedener innere Strukturen zur festigkeitsgerechten Gestaltung gewichtsoptimierter Bauteile vorgestellt. In beiden Fällen wird die Gestaltung mit Hilfe von FE-Modellen experimentell begleitet. / The new manufacturing possibilities offered by additive manufacturing not only allows to produce topologically novel components, but also enables to provide components with internal structures that are adapted to the component load or offer new possibilities for other functions. One approach is to use permeable internal structures, e. g. lattice structures, to realize efficient component cooling through the large internal surfaces created thereby. The effect of such a cooling is demonstrated by simulations and experiments using a simple example. As a further application example, the use of various internal structures for the strength-oriented design of weight-optimized components will be presented. In both cases the design is experimentally accompanied by FE models.