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OTIS: Osteopore Implant Shaper

Team members

Nicole Ng Sok Teng (Huang Xue Ting) (EPD), Alvina Chik (EPD), Revathi Ravindran (EPD), Ferry Chandra (EPD), Arissa Rashid (ISTD), Filbert Cia (ISTD)

Instructors:

Yeo Si Yong, Javier Gomez Fernandez

Overview

OTIS is an automated implant shaping system that efficiently and accurately shapes cranial implants.

Problem

Implants have to be shaped to fit the defect area of a patient's skull. However, the current implant hand-shaping* process is time consuming, laborious and inaccurate. Trained operators have to continuously hand shape the implant for 6-7 hours and qualitatively cross-check it against the ideal model to ensure that the implant is moulded to its desired shape.


*Implants are first 3D printed flat and then hand shaped by operators. Implants cannot be 3D printed directly as it would be unable to replicate the honeycomb structure required for bone regeneration

Introducing OTIS

Implant Shaping Made Easy

System Overview

Dynamic Heating

System maintains an implant-softening temperature range to speed up the shaping process

Automatic Shaping

Compression moulding eliminates the need for operators to hand shape the implants

Quality Check

System conducts a curvature analysis to validate the shape of the implant

Shape With Just One Click

Click me!

One Machine To Shape Them All

Mould implants of any shape and size

Interchangeable Moulds

Both the top and bottom moulds have a unique slotting mechanism that allow them to be easily slotted into the machine 

The slots are made of aluminium to withstand the compression force and temperature required to shape the implants

Quality Assurance At Every Step

 

 

Optimal Conditions

The temperature, compression force and position of components used by the system are experimentally-determined to ensure that the implant can be effectively heated and shaped without destroying its surface

Z-Scaling

Moulds are printed with weighted scaling to account for material spring-back. The edges of the moulds are also exaggerated to better shape the edges of the implant

Quality Check

The system has a built-in depth-sensing-camera which would retrieve a 3D scan of the moulded implant, and compare it against its ideal 3D model to return the percentage accuracy

Real-Time System Monitoring

 

 

Environment Monitoring

The control panel extends from the machine and allows operators to monitor the conditions and progress of the shaping process

Shaping Results

The ideal 3D model and the shaped implant have a similarity percentage* of 85% that is within Osteopore's acceptable threshold


*Similarity percentage is calculated by finding the number of points of intersection between the shaped implant mesh and the ideal 3d model mesh, divided by the total number of points in the shaped implant mesh

FEEDBACK

TEAM MEMBERS

student Nicole Ng Sok Teng (Huang Xue Ting) Engineering Product Development
student Alvina Chik Engineering Product Development
student Revathi Ravindran Engineering Product Development
student Ferry Chandra Engineering Product Development
student Arissa Rashid Information Systems Technology and Design
student Filbert Cia Information Systems Technology and Design

© 2022 SUTD

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