Orientador: Ruis Camargo Tokimatsu / Resumo: Na área da ortopedia a busca por novos avanços tecnológicos tem sido muito pouco e as pessoas que necessitam de dispositivos como órteses acabam sofrendo mais devido ao alto custo dos aparelhos ortopédicos. A maioria da população que possui patologias sofre por não ter renda suficiente para adquirir esses dispositivos e acabam agravando essas patologias. Este estudo busca inovar e propor a utilização de novas tecnologias para desenvolver órteses a essa população de baixa renda. Uma tecnologia de custo baixo e que possa ser implementada na rede pública. Através das análises feitas pelos profissionais da área como ortopedistas e terapeutas nas imagens bidimensionais dos exames do paciente consultados, com a utilização de aparelhos com a técnica de Engenharia Reversa será possível digitalizar o membro afetado ou posicioná-los de forma adequada para que seja tirado o molde da órtese personalizada. Esses aparelhos permitem utilizar dados de exames já feitos como Ultrassom, Ressonância Magnética, Tomografia ou Raio X e convertê-los em modelos tridimensionais. O objetivo deste projeto é utilizar essas técnicas de Engenharia Reversa para digitalizar o membro que necessite de auxílio e confeccionar as órteses com a tecnologia de Manufatura Aditiva, uma tecnologia que vem se desenvolvendo rapidamente nesses últimos anos e permitindo fabricar diretamente qualquer peça ou objeto através de um arquivo tridimensional modelado. Nos dias atuais, a Manufatura Aditiva tem sido utilizada em div... (Resumo completo, clicar acesso eletrônico abaixo) / Mestre

Accompagner l’intégration de la fabrication additive dans les grands groupes donneurs d’ordres devient crucial pour les sous-traitants. L’enseignement actuel des procédés et des règles de conception, limité à une vision techno-centrée, ne suffit pas pour projeter ses futures applications dans diverses industries telles que l’aéronautique, l’énergie, le médical, etc... D’un côté, les travaux sur la fabrication additive et les observations de terrain indiquent que les connaissances sur ses procédés, les matériaux et leur mise en œuvre sont régulièrement enrichies. D’un autre côté, les travaux de recherche en créativité montrent qu’il est possible de stimuler la capacité créative des individus pour les guider dans la génération d’idées et de concepts créatifs. Cette thèse explore alors un rapprochement possible entre créativité et fabrication additive, dans la perspective de proposer une méthode de créativité et des outils d’applications spécifiques au paradigme additif. Cette liaison vise à mettre en évidence des moyens de stimuler la créativité, dans le contexte spécifique de la fabrication additive. Cette approche a permis de faire émerger le rôle prépondérant des objets intermédiaires qui articulent les interactions entre plusieurs dimensions de la capacité créative : les motivations, les émotions, l’exploration des connaissances, l’alternance individu/collectif et l’organisation spatiale. Elle a aussi fait émerger le besoin de redéfinir les rôles de ces objets intermédiaires au regard de la fabrication additive. En ce sens, deux dispositifs opérationnels de stimulation, basés sur la manipulation d’objets tangibles, ont été conçus puis testés dans des contextes industriels. Les résultats expérimentaux montrent que l’exploration des connaissances matérialisées par ces dispositifs favorise la génération d’idées créatives qui peuvent ouvrir à de futures applications de la fabrication additive. Finalement, une méthode de Créativité par et pour la fabrication additive est proposée. Elle permet d’enrichir à la fois les pratiques méthodologiques des sciences de la conception et les pratiques opérationnelles sur deux terrains : celui de l’industrie de la fabrication additive et celui de l’innovation. / Emphasizing the integration of Additive Manufacturing (AM) into big industrial companies becomes crucial for subcontractors. Teaching additive processes and design rules is a techno-centric vision. It is not sufficient to project future applications of additive manufacturing in various industries such as aeronautics, energy, medical, etc. On one hand, the state of the art and field observations show that AM knowledge is steadily increasing. On the other hand, the state of the art about creativity shows that individuals creative capacity can be stimulated to guide them to the generation of creative ideas and concepts. This thesis then explores a possible linking between AM and creativity in order to propose a methodology and its application tools to stimulate creativity, in the specific context of additive manufacturing. This approach allowed us to bring out the major role of intermediate objects which articulate the interactions between several dimensions of the creative capacity: motivations, emotions, knowledge exploration, individual/collective work phases and spatial organization. It also highlighted the need for a new definition of intermediate objects’ roles regarding additive manufacturing. In this sense, we designed two operational devices, based on sensory manipulation of tangible objects, and tested them in real industrial contexts. Our experimental results show that the exploration of the knowledge embodied in these devices emphasizes the generation of creative ideas opening to potential applications of additive manufacturing. Finally, a model of Creativity Through Additive Manufacturing (CTAM) has been proposed. It enables us to contribute both to the methodological practices of design science and operational practices in two fields: the additive manufacturing industry and the field of innovation.

While tribology involves the study of friction, wear, and lubrication of interacting surfaces, the tribosurfaces are the pair of surfaces in sliding contact with a fluid (or particulate) media between them. The ubiquitous nature of tribology is evident from the usage of its principles in all aspects of life, such as the friction promoting behavior of shoes on slippery water-lubricated walkways and tires on roadways to the wear of fingernails during filing or engine walls during operations. These tribosurface interfaces, due to the small length scales, are difficult to model for contact mechanics, fluid mechanics and particle dynamics, be it via theory, experiments or computations. Also, there is no simple constitutive law for a tribosurface with a particulate media. Thus, when trying to model such a tribosurface, there is a need to calibrate the particulate media against one or more property characterizing experiments. Such a calibrated media, which is the “virtual avatar” of the real particulate media, can then be used to provide predictions about its behavior in engineering applications. This thesis proposes and attempts to validate an approach that leverages experiments and modeling, which comprises of physics-based modeling and machine learning enabled surrogate modeling, to study particulate media in two key particle matrix industries: metal powder-bed additive manufacturing (in Part II), and energy resource rock drilling (in Part III). The physics-based modeling framework developed in this thesis is called the Particle-Surface Tribology Analysis Code (P-STAC) and has the physics of particle dynamics, fluid mechanics and particle-fluid-structure interaction. The Computational Particle Dynamics (CPD) is solved by using the industry standard Discrete Element Method (DEM) and the Computational Fluid Dynamics (CFD) is solved by using finite difference discretization scheme based on Chorin's projection method and staggered grids. Particle-structure interactions are accounted for by using a state-of-the art Particle Tessellated Surface Interaction Scheme and the fluid-structure interaction is accounted for by using the Immersed Boundary Method (IBM). Surrogate modeling is carried out using back propagation neural network. The tribosurface interactions encountered during the spreading step of the powder-bed additive manufacturing (AM) process which involve a sliding spreader (rolling and sliding for a roller) and particulate media consisting of metal AM powder, have been studied in Part II. To understand the constitutive behavior of metal AM powders, detailed rheometry experiments have been conducted in Chapter 5. CPD module of P-STAC is used to simulate the rheometry of an industry grade AM powder (100-250microns Ti-6Al-4V), to determine a calibrated virtual avatar of the real AM powder (Chapter 6). This monodispersed virtual avatar is used to perform virtual spreading on smooth and rough substrates in Chapter 7. The effect of polydispersity in DEM modeling is studied in Chapter 8. A polydispersed virtual avatar of the aforementioned AM powder has been observed to provide better validation against single layer spreading experiments than the monodispersed virtual avatar. This experimentally validated polydispersed virtual avatar has been used to perform a battery of spreading simulations covering the range of spreader speeds. Then a machine learning enabled surrogate model, using back propagation neural network, has been trained to study the spreading results generated by P-STAC and provide much more data by performing regression. This surrogate model is used to generate spreading process maps linking the 3D printer inputs of spreader speeds to spread layer properties of roughness and porosity. Such maps (Chapters 7 and 8) can be used by a 3D-printer technician to determine the spreader speed setting which corresponds to the desired spread layer properties and has the maximum spread throughout. The tribosurface interactions encountered during the drilling of energy resource rocks which involve a rotary and impacting contact of the drill bit with the rock formation in the presence of drilling fluids have been studied in Part III. This problem involves sliding surfaces with fluid (drilling mud) and particulate media (intact and drilled rock particles). Again, like the AM powder, the particulate media, viz. the rock formation being drilled into, does not have a simple and a well-defined constitutive law. An index test detailed in ASTM D 5731 can be used as a characterization test while trying to model a rock using bonded particle DEM. A model to generate weak concrete-like virtual rock which can be considered to be a mathematical representation of a sandstone has been introduced in Chapter 10. Benchtop drilling experiments have been carried out on two sandstones (Castlegate sandstone from the energy rich state of Texas and Crab Orchard sandstone from Tennessee) in Chapter 11. Virtual drilling has been carried out on the aforementioned weak concrete-like virtual rock. The rate of penetration (RoP) of the drill bit has been found to be directly proportional to the weight on bit (WoB). The drilling in dry conditions resulted in a higher RoP than the one which involved the use of water as the drilling fluid. P-SATC with the bonded DEM and CFD modules was able to predict both these findings but only qualitatively (Chapter 11)

Submitted by Jean Medeiros (jeanletras@uepb.edu.br) on 2018-05-24T13:45:49Z No. of bitstreams: 1 PDF - Inácio Costa Neto.pdf: 37706583 bytes, checksum: 2e6b9e65c5857fc8eda45146b4f4d0bb (MD5) / Approved for entry into archive by Secta BC (secta.csu.bc@uepb.edu.br) on 2018-06-05T11:34:00Z (GMT) No. of bitstreams: 1 PDF - Inácio Costa Neto.pdf: 37706583 bytes, checksum: 2e6b9e65c5857fc8eda45146b4f4d0bb (MD5) / Made available in DSpace on 2018-06-05T11:34:00Z (GMT). No. of bitstreams: 1 PDF - Inácio Costa Neto.pdf: 37706583 bytes, checksum: 2e6b9e65c5857fc8eda45146b4f4d0bb (MD5) Previous issue date: 2017-04-17 / This work seeks to perform a mapping of the production process for Good Manufacturing Practices in Additive Manufacturing in the Laboratory of Three Dimensional Technologies of the Nucleus of Technology for Health of the State University of Paraíba based on chapter five of RDC 16/13, in order to Possible future preparation of a manual of good manufacturing practices of this laboratory. This is a theoretical work in order to guarantee methodologies to extract the maximum quality of the process in question, aiming to provide guarantees of reliability, reproducibility and predictability of the biomodels produced, through standards, manuals, methods and resolutions when manufacturing medical products Such as surgical guides, temporary or permanent prostheses and orthoses. This work is justified on the assumption that biomodels are already being manufactured, but that they do not follow the necessary method in order to optimize the manufacturing process, thus spending too much time and financial resources. With this, it was possible to guarantee that the process is carried out following a layout for the laboratory that will facilitate the manufacture of the biomodel, and the creation of a flow chart proper to good manufacturing practices, allowing each agent to have its own function. / Este trabalho busca realizar um mapeamento do processo de produção para as Boas Práticas de Fabricação em Manufatura Aditiva no Laboratório de Tecnologias Tridimensionais do Núcleo de Tecnologia para Saúde da Universidade Estadual da Paraíba baseando-se no capítulo cinco da RDC 16/13, a fim de possibilitar a futura elaboração de um manual de boas práticas de fabricação deste laboratório. Trata-se e um trabalho teórico a afim de garantir metodologias que permitam extrair a máxima qualidade do processo em questão, objetivando proporcionar garantias de fidedignidade, reprodutibilidade e previsibilidade dos biomodelos produzidos, por meio de normas, manuais, métodos e resoluções ao fabricar produtos médicos específicos como guias cirúrgicos, próteses provisórias ou permanentes e órteses. Justifica -se esse trabalho a partir do pressuposto que já existem biomodelos sendo fabricados, mas que não seguem o método necessário a fim de avalizar a fabricação de maneira otimizada, gastando assim tempo e recursos financeiros em demasia. Com isso, foi possível garantir que o processo seja realizado seguindo um layout para o laboratório que facilitará a manufatura do biomodelo, e a criação de um fluxograma próprio para as boas práticas de fabricação, permitindo que cada agente tenha sua própria função.

Orientadora: Profª. Drª. Maria Elizete Kunkel / Dissertação (mestrado) - Universidade Federal do ABC. Programa de Pós-Graduação em Engenharia Biomédica, 2017. / A reconstrução auricular está presente desde 600 a.C. na forma de implante de retalhos de pele. Nos últimos anos, tem ocorrido cada vez mais pesquisas sobre o desenvolvimento de próteses que visam substituir um órgão do paciente sem a necessidade de realização de cirurgias. Novas tecnologias, como processos de aquisição da anatomia e manufatura aditiva, têm sido investigadas como alternativa para a produção de próteses auriculares com uma melhor relação custo/qualidade quando comparada com o processo manual. Nesta pesquisa foi desenvolvida uma metodologia para investigar o uso de quatro métodos de aquisição da estrutura externa do pavilhão auricular de uma voluntária (fotogrametria, escaneamento 3D, reconstrução 3D de imagens de tomografia computadorizada e modelagem 3D parametrizada) para a produção de moldes de prótese auricular por manufatura aditiva (técnica de deposição de material fundido). As próteses auriculares de silicone produzidas com esta metodologia apresentaram um excelente resultado estético com menos 3% de erro dimensional. Além disso, análises mecânicas (ensaios de resistência à tração e dureza) do silicone utilizado revelaram que as próteses produzidas apresentam ótima resistência mecânica que não é alterada pelo processo de pigmentação. Ensaios com pele suína mostraram que, dos quatro adesivos analisados, três apresentaram força de adesão satisfatória. Os resultados demonstram a viabilidade de uma metodologia acessível para a produção de próteses de orelhas utilizando softwares livres, tecnologias e suprimentos disponíveis no mercado brasileiro. / The auricular reconstruction is present since 600 BC through skin flaps implants. In the current years, prostheses have been developed to replace the patient's organ without the use of surgeries. Recently, new technologies, such as anatomical acquisition and additive manufacturing techniques are being applied in the production of auricular prostheses, aiming at obtaining a product with better cost/quality relation when compared to the manual manufacturing process. In this research, a methodology was developed to investigate the use of four methods to acquire the external structure of a volunteer's ear (photogrammetry, 3D scanning, 3D reconstruction of computed tomography images and parameterized 3D modeling) for the production of auricular prosthesis molds by additive manufacture (melt deposition technique). The silicone ear prosthesis produced with the presented methodology shows an excellent esthetic result with only 3% dimensional error. In addition, mechanical analysis (tensile strength and hardness tests) of the used silicone showed that the produced prostheses has excellent mechanical resistance that is not altered by the pigmentation process. Tests with swine skin showed that, of the four analyzed adhesives , three had satisfactory adhesion strength. The results demonstrate the feasibility of an accessible methodology for the production of ear prostheses using free softwares, technologies and supplies available in the Brazilian market.

Les composites à matrice titane (CMTi) sont des matériaux attractifs pour des applications aéronautiques, en raison de leurs performances mécaniques à haute température et de leur faible densité. La difficulté d’usiner ce type de matériaux rend les procédés de fabrication additive intéressants pour la fabrication de pièces complexes en trois dimensions. Cette étude porte sur l'élaboration de composites à matrice titane par le procédé de fabrication additive par fusion laser de poudre projetée. Dans un premier temps, différents types de poudres- renfort et de préparations de poudre ont été utilisés pour faciliter la mise en œuvre du procédé additif, dans le but d’obtenir des microstructures homogènes. Dans un second temps, l’étude s’est concentrée sur le mélange Ti-6Al-4V / B4C formant des renforts TiB et TiC par voie in-situ dans une matrice de Ti-6Al-4V. Les mécanismes de formation des microstructures obtenues ont pu être expliqués puis une étude des propriétés mécaniques (dureté, module d’Young et comportement sous une sollicitation en traction à chaud et à l’ambiante) a été réalisée afin d’évaluer l’effet du renforcement sur les propriétés mécaniques du matériau. Parmi les résultats importants ce cette étude, la présence de taux de carbone élevés en solution solide dans la matrice de titane a été évoqué comme étant le facteur prédominant dans l'augmentation des propriétés mécaniques avec le taux de B4C. / Titanium matrix composites are attractive materials for aeronautical applications, mainly because of their superior mechanical resistance at elevated temperature, combined with a low density. The critical machinability of such composites makes additive manufacturing processes particularly adapted for building complex 3D shapes. This study has been focused on the Direct Metal Deposition (DMD) of Metal matrix composites. In a first step, various powders and powder blends have been carried out in order to facilitate the DMD process and to obtain homogeneous microstructures. Following this, Ti-6Al-4V / B4C powder blends, allowing to obtain TiB + TiC particles distributed in the Ti matrix were more specifically considered. Metallurgical mechanisms involved in the formation of microstructures were identified prior to an investigation on mechanical properties at ambient and elevated temperature for various DMD process conditions and particle concentrations. Among the most interesting results of this study, the influence of a high carbon content solubilized in the Ti-matrix was considered as a dominant factor to explain the evolution of mechanical properties with increased amounts of reinforcements.

Ultrasonic Consolidation (UC) is a solid state additive manufacturing process which fabricates three-dimensional objects by ultrasonically joining metal foils together, layer-bylayer, to form a solid part. A wide range of materials can be used to fabricate parts by UC and products with complex internal geometry can be generated by shaping the crosssection throughout the build using Computer Numerically Controlled (CNC) milling. As a result of its ability to embed various secondary materials and fibres in metal matrices, UC has emerged as a potential method of fabricating multi-functional materials and structures.

La radiologie interventionnelle percutanée permet le diagnostic ou le traitement de tissus cancéreux grâce à l'utilisation d'aiguilles et d'un guidage par imageur. Bénéfique pour le patient, ce type de procédure clinique est en revanche complexe pour le radiologue. Afin de lui apporter une assistance et de contrôler l'aiguille de manière déportée, nous proposons dans ces travaux de réaliser des dispositifs robotisés compliants, donc monoblocs, et multi-matériaux en exploitant la fabrication additive multi-matériaux. Pour y parvenir, nous proposons plusieurs solutions pour réaliser les fonctions cinématique, d'actionnement et de perception. En particulier, nous proposons une nouvelle liaison compliante, la liaison HSC, ainsi qu'un nouvel actionneur pneumatique pour l'insertion d'aiguille. Nous démontrons finalement les apports de la fabrication additive pour la robotique médicale en combinant l'ensemble de ces solutions dans un dispositif assurant un contrôle à distance de l'aiguille. / Percutaneous interventional radiology permits the diagnosis or the treatment of cancer tissues thanks to the use of needles and imaging devices. Being minimally invasive, such procedures are beneficial for the patient, but for the radiologist, they are highly complex. In order to assist the physician and remotely control the needle, we propose in this work the design and the manufacturing of multi-material compliant devices by taking advantage of multi-material additive manufacturing. To perform the design of such device, we propose several solutions in terms of kinematics, actuation and sensing. In particular, we developed a new compliant joint, the HSC joint, as well as a new pneumatic actuator for needle insertion. In the end, we demonstrate in the thesis the contributions of multi-material additive manufacturing for medical robotics, by combining all those solutions into a single device that remotely controls both the orientation and the insertion of the needle

Detta examensarbete har utförts i Karlskoga på två företag, Lasertech LSH AB och PartnerTech Karlskoga AB, där uppdraget bestod i att med en metodutveckling hitta ett generellt angreppssätt som man kan förhålla sig till för att förenkla efterbearbetningen av en additivt tillverkad (AT) detalj. Fortsättningsvis kommer additiv tillverkning att benämnas AT i texten. Svårigheten ligger i att spänna upp och mäta in en detalj i en CNC-maskin som nästan är färdig och saknar självklara inmätning- och inspänningsytor. Syftet med arbetet var att hitta en generell metod att använda sig av för att lösa dessa svårigheter vilket leder till en säkrare och effektivare tillverkning. Parallellt med problemlösningen gjordes även en fallstudie där bägge företagen har en AT produkt som ska bearbetas i CNC-maskin. Problemen klargjordes med hjälp av ett funktionsmedelträd och lösningar togs fram med hjälp av konceptgenerering för att få fram så många och bra lösningar som möjligt. Genom att ta fram dessa koncept och möjligheten att kombinera dessa med varandra skapades en metod som löser inmätning- och inspänningsproblemen och visade sig vara användbar i fallstudien. Dessa koncept ses som en generell och bra lösning på ovanstående problem. Fortsatt arbete och utbildning kommer att krävas för att ytterligare testa metoderna och ge ökad kunskap om AT för att underlätta tillverkningsprocessen. / This thesis has been carried out in Karlskoga at the two companies, Lasertech LSH AB and PartnerTech Karlskoga AB, where the assignment consisted of using a methodological development to find a general approach that can be used to simplify the processing of an additive manufactured (AM) part. The challenge is to rig and calibrate a detail in a CNC machine that is nearly finished that lacks obvious faces to rig and calibrate the part in the machine. The aim of the work is to find a general method that can be used to resolve these difficulties, leading to a safer and more efficient manufacturing. Parallel to the solution of the problem, a case study will also be done where both companies have a product that will be additive manufactured (AM) and processed in the CNC machine. The problems were clarified by using a functional-medium-trees (funktionsmedelträd) and solutions were developed using the concept generation to get as many good solutions as possible. By developing these concepts and the ability to combine these with each other a method that solves the problems with the rigging and calibration was created and proved to be useful in the case study. We see these concepts as general and a good solutions to the problems above. Further work and training will be required to further test the methods and increase knowledge about AM production to facilitate the manufacturing process.

Eurocoating, Italy, is a company that works in the biomedical sector. They have for a long time created prostheses from CAD files achieved from customers, and now they want to build their own expertise about the design. The thesis work was a part of a three year long collaborative research project between Eurocoating and University of Trento that was aiming to investigate the prostheses with open-porous surface and trabecular structure, created by Selective Laser Melting. The purpose of the thesis was to investigate and characterize 30 different trabecular structures of Ti-6Al-4V, fabricated by Selective Laser Melting. That includes investigation the effect on the morphology and porosity fraction caused by the manufacturing and the effect on mechanical and physical properties due to the different characterizations of the structures. The thesis work had its foundation in literature studies to receive deep knowledge about the subject. Practical tests were performed to investigate mechanical behaviour under compressive and tensile loading, static friction and wear resistance. The findings from these tests were compared to the porosity fraction and the morphological characterizations. The result stated that the porosity fraction was lower than the designed porosity, and that is was strongly influenced by size of the voids and struts. The strut thickness was higher than the design values, especially on the lateral surface, while the voids size were approximately as designed. Result from the compression test showed a trend of decreasing stiffness and strength with increasing porosity fraction. Also structures with same porosity fraction could have a wide range in mechanical properties which indicates high dependence on the morphological geometry i.e. pore size and shape, strut size and pore distribution. Comparisons between tensile and compression behaviour stated that the structures had a lower strength but a significant higher stiffness in tensile load. All structures from the wear test showed a good resistance while the results from the friction test needs further investigation to be fully understood. The physical and mechanical properties of the trabecular structures was found to be close to those of cortical and trabecular bone in porosity, stiffness and strength. There is a range of variations leading to possibilities to adopt the application depending on customer. Thus, these can be considered as promising structures used biomedical application to optimize osseointegration and secondary long term fixation.