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.

A variety of high-permittivity (high-k) and low-loss ceramic-thermoplastic composite materials as fused deposition modeling (FDM) feedstock, based on cyclo-olefin polymer (COP) embedded with sintered ceramic fillers, have been developed and investigated for direct digital manufacturing (DDM) of microwave components. The composites presented in this dissertation use a high-temperature sintering process up to 1500°C to further enhance the dielectric properties of the ceramic fillers. The electromagnetic (EM) properties of these newly developed FDM composites were characterized up to the Ku-band by using the cavity perturbation technique. Several models for prediction of the effective relative dielectric permittivity of composites based on the filler loading volume fraction have been evaluated, among which Hanai-Bruggeman and Maxwell models have shown the best accuracy with less than 2% and 5% discrepancies, respectively. The 30 vol. % COP-TiO2 FDM-ready composites with fillers sintered at 1200°C have exhibited a relative permittivity (εr) of 4.78 and a dielectric loss tangent (tan δd) lower than 0.0012 at 17 GHz. Meanwhile, the 30 vol. % COP-MgCaTiO2 composites with fillers sintered at 1200°C have exhibited a εr of 4.82 and a tan δd lower than 0.0018. The DDM approach combines FDM of the engineered EM composites and micro-dispensing for deposition of conductive traces to fabricate by 3D-printing edge-fed patch antennas operating at 17.2 GHz and 16.5 GHz. These antennas were demonstrated by employing a 25 vol. % COP-MgCaTiO2 composite FDM filament with the fillers sintered at 1100°C and a pure COP filament, which were both prepared and extruded following the process described in this dissertation. The low dielectric loss of the 25 vol. % COP-MgCaTiO2 composite material (tan δd lower than 0.0018) has been leveraged to achieve a peak realized gain of 6 dBi. Also, the high-permittivity (εr of 4.74), which corresponds to an index of refraction of 2.17, results in a patch area miniaturization of 50% when compared with an antenna designed and DPAM-printed over a Rogers RT/duroid® 5870 laminate core through micro-dispensing of CB028 silver paste. This reference antenna exhibited a measured peak realized gain of 6.27 dBi that is comparable. Also, two low-loss FDM-ready composite materials for DDM technologies are presented and characterized at V-band mm-wave frequencies. Pure COP thermoplastic exhibits a relative permittivity εr of 2.1 and a dielectric loss tangent tan δd below 0.0011 at 69 GHz, whereas 30 vol. % COP-MgCaTiO2 composites with fillers sintered at 1200°C exhibit a εr of 4.88 and a tan δd below 0.0070 at 66 GHz. To the best of my knowledge, these EM properties (combination of high-k and low-loss) are superior to other 3D-printable microwave materials reported by the scientific microwave community and are on par with materials developed for high-performance microwave laminates by RF/microwave industry as shown in Chapter 5 and Chapter 7 and summarized in Table 5.4 and Table 7.1. Meanwhile, the linear coefficient of thermal expansion (CTE) from -25°C to 100°C of the reinforced 30 vol. % COP-MgCaTiO2 composite with fillers sintered at 1200°C is 64.42 ppm/°C, which is about 20 ppm/°C lower when compared with pure ABS and 10 ppm/°C lower as compared to high-temperature polyetherimide (PEI) ULTEM™ 9085 resin from Stratasys, Ltd. The CTE at 20°C of the same composite material is 84.8 ppm/°C which is about 20 ppm/°C lower when compared with pure ABS that is widely used by the research community for 3D printed RF/microwave devices by FDM. The electromagnetic (EM) composites with tailored EM properties studied by this work have a great potential for enabling the next generation of high-performance 3D-printed RF/microwave devices and antennas operating at the Ku-band, K-band, and mm-wave frequencies.

Les changements sociétaux tels que la personnalisation de la médecine, ainsi que la volonté de mieux comprendre la biologie de l’os modifie notre approche de fabrication des biomatériaux. Ces derniers se doivent ainsi d’être sur-mesure, c’est-à-dire capables de répondre à une problématique particulière. Ceci implique plus précisément dans le cas qui nous intéresse, à savoir l’os, la maîtrise de leur architecture et de leur comportement en milieu biologique (e.g., biodégradabilité).Malgré leurs atouts incontestables pour ce domaine, les biocéramiques en hydroxyapatite (HA) restent cantonnées à des usages modestes (e.g., comblement de petits défauts) ; en cause, des propriétés de biodégradation, d’ostéoconduction ou encore d’ostéoinduction souvent inadaptées aux problématiques contemporaines. Pour pallier ces limitations, nous avons entrepris deux voies de modulation des propriétés biologiques de l’HA, une voie « chimique », basée sur l’incorporation d’ions carbonate dans la structure apatitique, et une voie « procédé », reposant sur le potentiel de la fabrication additive.Des poudres d’hydroxyapatites phosphocalciques carbonatées (CHA) ont été préparées. Les ions carbonate pouvant occuper les sites hydroxyle et phosphate de l’HA, une méthode de quantification sélective du taux de substitution sur chacun de ces sites a été mise au point. Cette méthode spectroscopique novatrice ouvre de nombreuses opportunités d’études appliquées et fondamentales des CHA, abordées dans ce manuscrit, et constitue également un outil qui pourrait se révéler précieux dans l’optique de mise sur le marché de dispositifs médicaux en CHA (e.g., norme ISO).Basé sur une technologie de fabrication additive, un procédé de fabrication de biocéramiques d’architecture complexe, reproductible, flexible, fiable, de haute précision ( 5 µm) et peu coûteux, a été développé et optimisé. Cet outil de fabrication a été mis en œuvre pour répondre à des questions biologiques à finalité fondamentale et thérapeutique. / The current approach to produce biomaterials tends to evolve due to societal change such as the development of personalized medicine or the eagerness to better understand bone biology. Hence, biomaterials, which specifications depends of their intended applications, have to be custom made. For bone tissue engineering, this implies to control the scaffold architecture and behaviour in a biological environment (e.g., biodegradability).Despite their indisputable qualities, the use of hydroxyapatite (HA) bioceramics tend to be limited to basic applications (e.g. filling small defects) because of biodegradation, osteoconduction, or osteoinduction properties that do not match the actual needs. To exceed these limitations, we explored two modifications paths to tune HA biologic properties: a “chemical” approach based on incorporation of carbonate ions into apatitic structure, and a “process” approach, built around additive manufacturing singular potential.Carbonated phosphocalcic hydroxyapatites (CHA) powders were prepared. As carbonate ions may occupy HA hydroxyl and phosphate sites, a selective method to quantify their ratio in each site by IR spectroscopy has been developed. This innovative spectroscopic method opens numerous opportunities for applied and fundamental studies of CHA, but could also be considered as a precious standard for a future release of CHA medical devices (e.g. ISO norm).A cheap, flexible, robust and reliable manufacturing process based on an additive manufacturing technology has been developed and optimized, leading to the production of bioceramics with complex architectural features (accuracy  5 µm).This manufacturing process has been implemented in biological studies with fundamental and therapeutic purposes.

Significant efforts have been made in the last decades to decrease the world’s dependency to fossil fuels. One of the fronts which has shown major improvement is gas turbine efficiency. To this end, components such as recuperators have been developed to recover heat that is usually trapped and wasted in the exhaust gases of combustion processes. Brayton Energy Canada has recently developed a promising compact heat exchanger that could be used as a recuperator in gas turbines. Nevertheless, this novel type of wire mesh heat exchanger still has room for improvement, especially regarding the way that its fin arrays are manufactured due to the fact that the technique presently used is time consuming and consequently costly. The present research aims to manufacture near-net shaped pin fin arrays using cold gas dynamic spray as an additive manufacturing technique by selectively covering the substrate by the means of a mask. Moreover, this research work studies the feasibility of using CGDS as an additive manufacturing technique to produce pin fin arrays, the thermal and hydrodynamic performances of this new type of pin fin created, the effect of geometric parameters such as fin density and height on the performances, the viability of the sprayed pin fins in a real environment by means of finding mechanical properties such as adhesion strength, the possibility of producing a streamwise material anisotropic fin arrays, and finally the different adhesion mechanisms by means of numerical modeling of the relevant impact physics.