KU Leuven, J.P. Kruth, P. Mercelis, L. Froyen, M. Rombouts

SINTEF, Casper van der Eijk, Olav Åsebø, Øyvind Kolnes, Terje Mugaas, Roald Karlsen, Rune Skjevdal and Klas Boivie.

Dr.-Ing. Dirk Godlinski,  Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung (IFAM)

Professor Phill Dickens, Loughborough University, England

RM is starting to have an impact on the way designs are formulated and then on how parts are produced. This paper discusses the wide variety of impacts on the Virtual and Physical Prototyping that is being undertaken and will be in the future. Many changes will need to occur in both of these areas with Physical Prototyping becoming less important and Virtual Prototyping become paramount.

J.-P. Kruth, B. Vandenbroucke, J. Van Vaerenbergh, P. Mercelis

Division PMA, Department of Mechanical Engineering, Katholieke Universiteit Leuven, Belgium

    E Boillat, S Kolosov, R Glardon, Ecole Polytechnique Federale de Lausanne, Switzerland
    M Loher, D Saladin and G Levy, University of Applied Sciences, St.Gallen, Switzerland

An iterative method to optimize non-linear production processes is described. In contrast to classical design-of-experiment methods, it starts with a small number of experiments, based on which a preliminary data-based model is developed. From this model a vector of process parameters with (potentially) improved performance is calculated.

P.Fischer, V.Romano, University of Bern, Switzerland
H. Weber , S.Kolossov, Swiss Federal Institute of Technology, Lausanne, Switzerland

P. Berce1, H. Chezan1, N. Balc Technical University of Cluj-Napoca, Department of Manufacturing Engineering, Romania

The paper presents the manufacturing process of the custom implants, used for skull reconstruction.

Medical applications are some of the most interesting applications of the rapid prototyping and manufacturing technologies. These technologies are able to produce a physical model of the anatomic structures, which is very useful for diagnosis, surgery planning, training, and for design and manufacture of the custom implants.

Ralf Schindel  FHS Hochschule für Technik, Wirtschaft und Soziale Arbeit, St. Gallen, Switserland

F. Klocke, C. Wagner, C. Ader, Fraunhofer-Institute of Production Technology IPT, Germany

Ralf Schindel  FHS Hochschule für Technik, Wirtschaft und Soziale Arbeit, St. Gallen, Switserland

Laura Castillo, AIMME (Instituto Tecnológico Metalmecánico), Valencia, Spain

Laura Castillo, AIMME (Instituto Tecnológico Metalmecánico), Valencia, Spain

Ana Cruz García, Instituto de Biomecánica de Valencia, Spain

The objective of this paper is to present a new service concept of Simulation Service Provider for orthopaedic surgery (ORTHOSIM), aimed at the health community and implant industry. ORTHOSIM service shall offer virtual analyses the implant behaviour after implantation in a customized implant-patient configuration. It will be presented in e-challenges.

T. Laoui, S. K. Shaik, University of Wolverhampton, UK E. Santos, K. Osakada, M. Shiomi, M. Morita, F. Abe, University of Osaka, Japan N.K. Tolochko, National Academy of Sciences of Belarus, Belarus

This paper discusses the influence of various process parameters on the characteristics of medical implants made by laser forming involving both laser sintering and laser melting. The mechanical properties of the laser processed medical implants are reported.

Edson Costa Santosa, Masanari Shiomia, Kozo Osakadaa Department of Mechanical Science and Bioengineering, Osaka University, Japan Tahar Laoui School of Engineering and Built Environment, University of Wolverhampton, Wolverhampton, UK

This paper presents an overview on the various research efforts deployed in the past decade or so towards the manufacture of metal components by different laser processing methods using different commercial machines. The materials and applications suitable to rapid manufacturing of metal parts by these techniques are also discussed.

Kenny Dalgarno, University of Leeds, UK

This paper outlines the current state of the art in the customisation of medical devices and implantable parts and systems, presents details of some projects which are ongoing at the University of Leeds, and outlines future research directions in this field.

Slavko Dolinsek, University of Ljubljana & RTCZ, Slovenia; Chris Lewis Jones, Delcam plc, United Kingdom, Rafael Valero, AIJU, Spain; Anton Gerrits, TNO Science & Industry, The Netherlands

The ambitious scope of the European initiative CUSTOM-FIT, a Framework 6 Integrated Project, is to create a fully integrated system for the design, production and supply of individualized products. Personalized to fit geometrically and functionally the requirements of the citizen for (initially) the medical & consumer goods sectors.

Klas Boivie, NTNU, Department of Production and Quality Engineering, Norway

Roald Karlsen, SINTEF Technology and Society, Production Engineering, Norway

Casper van der Eijk, SINTEF Materials and Chemistry, Metallurgy, Norway

Presented at The 17th Solid Freeform Fabrication Symposium, August 14.-16. 2006, Austin, Texas, USA

The Metal Printing Process (MPP) is a novel Rapid Manufacturing process under development at SINTEF and NTNU (Norwegian University of Science and Technology) in Trondheim, Norway. This paper addresses some of the most critical material issues at the current development stage of MPP, and the present solutions to these.

G.E. Knoppers, J. Dijkstra, W.P. van Vliet, TNO Science and Industry, The Netherlands

RM utilizes the application of different materials in parts by stacking a sequence of layers. Based on the requirements of the part, mixtures of materials, so-called Functionally Graded Materials, can be used to compose the product functionality. TNO developed a new computer tool which enables the user to specify Functionally Graded Materials.

Ralf Becker, Andrzej Grzesiak, Axel Henning, Fraunhofer Institute Manufacturing Engineering and Automation (IPA), Germany

RM processes provide designers, mechanical and process engineers with a lot of changes and opportunities. It is necessary to show them, how their work and processes will change due to these new technologies.

Dr. Martin Hedges, Neotech Services MTP, Germany

This paper, originally presented at the  "Cost Effective Manufacture via Net Shape Processing"  NATO-RTO AVT - 139 conference introduced the Laser Engineered Net Shaping (LENS)technology for RM, modification and repair of aerospace and defence components in high performance materials such as titanium, nickel, cobalt and steel alloys.           

Philip Delamore, Research Fellow London College of Fashion

High performance football boots for professional players have the potential to take the proof-of-concept of an approach focusing on highly individualized products to a market success. At the same time, they point to a long term strategy to enable the development of the manufacturing technologies involved to a cost and performance level that would serve in the production of consumer products on a mass customization scale.

This paper presents the background, motivation and research targets of a research project dealing with various finishing technologies to influence the performance of laser sintered parts with the focus on football boot out soles for professionals.

Soumya Banerjee & Prof. David Ian Wimpenny, RP & RM Group, Faculty of Computing Sciences & Engineering, DeMontfort University, UK