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Designing individualized medical devices requires the collection of anthropometric data from the patient. This can be done by using the 3D scanning process. Despite many advantages, it has significant drawbacks, limiting the suitability of its use for many types of medical devices. This paper presents the design of measuring station that allows to increase the quality of anthropometric data obtained in the scanning process of humans limbs. Accuracy and repeatability of data obtained on the station is presented and compared to reference scans. What's more, thanks to the automatisation of certain activities in the scanning process, operating the device requires the operator to have much lower competencies and workload.

The paper presents experimental process of manufacturing individualized prosthetic sockets out of thermoplastic material, using an additive manufacturing technology of Fused Deposition Modelling. The patient is an adult male with an amputated forearm. His stump was 3D scanned using a low-cost 3D scanner in a semi-automated manner. Then, the anthropometric data was used for creation of a model of a prosthetic socket, which was then manufactured. Three different 3D printers were used, with three different materials (ABS, nylon and PC) and three different sets of process parameters. The paper contains descriptions of the process, its results and opinions by the patient, leading to selection of an optimal process course variant.

Pre-operative preparation of the surgeon is more and more often extended to individual patient's anatomical models depicting the ill organ and the existing change in relation to the surrounding structures (e.g. blood vessels). Among the models there are models of the skeletal system, to which the FFF technology is used. Models of parenchymal organs are more difficult to reproduce due to material limitations in FFF technology, which is why alternative technologies such as PolyJet and SLA are used. Due to the high price of models, they are less frequently used in, especially in Polish hospitals. The research presented in the article deals with the subject of modification of the existing methodology of rapid production of pre-operative models with the use of various low-budget techniques of rapid manufacturing, which use materials of low hardness, similar to human soft tissues. The aim is to create a methodology and determine the parameters of materials that allow for the cheap production of functional pre-operational aids.

The paper presents design and manufacturing process of an individualized wrist orthosis. The patient’s upper limb was 3D scanned and the orthosis was design using a CAD system. Each part of the orthosis consists of two different materials, that fulfill different functions. By using the double-head Fused Deposition Modelling machine it was possible to produce theses parts in a single process without the need for additional assembly operations. The orthosis has been tested for mutual fit of parts, strength and comfort of use.

Inter-operational surgery supplies manufactured additively using the FDM (Fused Deposition Modelling) technology are required to be sterilized before use. After manufacturing, the part should be sterilized using one of commonly used processes, without losing its dimensions and shape. The paper presents studies on manufacturing and sterilizing samples made out of ABS material and influence of the sterilization process on the dimensional accuracy of these samples.

Realism of a Virtual Reality simulation can be improved by use of physical objects tracked in real time. The paper presents possibility of using low-cost FDM process, realized by MakerBot Replicator 2X machine, in comparison with a professional one to build tooling for a simulation of ultrasound examination procedure. The objects were manufactured on two different machines out of ABS material, 3D scanned for accuracy testing and finally possibilities of their use in a VR system were evaluated.

The paper presents design and manufacturing process of an individualized ankle orthosis using additive manufacturing technologies and reverse engineering. Conventional processes of manufacturing of orthosesareexpensive and time consuming -an alternative method was proposed. The patient’s leg was 3D scanned and the orthosis was designed using a CAD system. It was then manufactured using the Fused Deposition Modelling technology, assembled and fully tested. Positive results were obtained.

This paper describes prototyping of an individualized cosmetic arm prosthesis. Aim of the studies was to obtain an anatomically correct, lightweight prosthesis. It was accomplished using additive manufacturing technology of fused deposition modeling. The data was obtained by 3D scanning. An experimental concept of dual extrusion of two different materials was applied – the prosthesis was divided into an elastic shell and a rigid core, manufactured in one process. Obtained results were positive.

This paper presents assessment of the Rapid Prototyping finishing techniques for the printed components. The aim of the study was to compare the element printed with FDM technology before and after the treatment, using 3D scanning techniques. The object was scanned right after manufacturing, then was subjected to finishing treatment and was 3D scanned once again. Assessment of the results was performed using the GOM Inspect software, based on a comparison between scans and nominal model.

Numerous experimental studies, including experiments performed by the authors, have shown that the part orientation during layer deposition has a very strong influence on final strength of a product manufactured by additive Fused Deposition Technology. The paper presents the results of tensile, bending and impact strength tests performed on samples of various orientations, made out of ABS material using FDM technology. The results of these tests allowed discovering a unique phenomenon – with the changing orientation, not only the values of strength indexes change, but macroscopic material behavior under load as well. The transition between a “yield point” and “brittle” material usually happens in a certain range of orientation values, named a critical orientation by the authors. The paper indicates supposed ranges of critical orientation for various types of loads.

The paper presents a method, developed by the authors, for manufacturing polymer composites with the matrix manufactured in a layered manner (via 3D printing – Fused Deposition Modeling) out of a thermoplastic material. As an example of practical application of this method, functional prototypes are presented, which were used as elements of foundry tooling – patterns for sand molding. In case of manufacturing prototype castings or short series of products, foundries usually cooperate with modeling studios, which produce patterns by conventional, subtractive manufacturing technologies. If patterns have complex shapes, this results in high manufacturing costs and significantly longer time of tooling preparation. The method proposed by the authors allows manufacturing functional prototypes in a short time thanks to utilizing capabilities of additive manufacturing (3D printing) technology. Thanks to using two types of materials simultaneously (ABS combined with chemically hardened resins), the produced prototypes are capable of carrying increased loads. Moreover, the method developed by the authors is characterized by manufacturing costs lower than in the basic technology of Fused Deposition Modeling. During the presented studies, the pattern was produced as a polymer composite and it was used to prepare a mold and a set of metal castings.

The paper presents results of studies undertaken by the authors, aimed at determination of character of influence of marker arrangement on real-time measurement of position and orientation of an object, using an exemplary optical tracking system PST-55. Such a system can be used for interaction in immersive Virtual Reality applications. To ensure better immersion of a user in a virtual environment, it is necessary to directly translate its actions into 3D image presented by the VR application. It is possible, among other things, by the application of systems for tracking user’s movements. During the presented studies, an object with infrared-reflective markers deployed on its surface was placed in the center of a rotary table, then it was measured by the tracking system to determine the influence of the object angular position on the accuracy of determination of its position and orientation by the examined device. The measurements were performed for several different arrangements of markers, to formulate guidelines for their deployment on objects used for work in a virtual environment.

The paper presents the results of experimental study – part of research of additive technology using thermoplastics as a build material, namely Fused Deposition Modelling (FDM). Aim of the study was to identify the relation between basic parameter of the FDM process – model orientation during manufacturing – and a dimensional accuracy and repeatability of obtained products. A set of samples was prepared – they were manufactured with variable process parameters and they were measured using 3D scanner. Significant differences in accuracy of products of the same geometry, but manufactured with different set of process parameters were observed.