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The paper presents results of research conducted on a batch of additively manufactured individualized openwork wrist&ndash, hand orthoses made of thermoplastics and designed automatically based on 3D-scanned geometry of a given patient. The aim of the work was to establish an automated design process and find a reliable set of parameters for rapid and affordable manufacturing of usable orthoses on popular 3D printers, with little or no supervision of the process. The paper presents motivations, methodology of automated design, plan of manufacturing and testing, the obtained results in terms of process stability, fit and assessment by patient and strength of the obtained orthoses. Almost 100 manufacturing processes of ready-to-use orthosis parts were carried out in a controlled environment and their results were analyzed thoroughly. The results are promising, as most of the obtained products fulfil the strength criteria, although not all of them meet the economic criteria. As a result, a recommended set of process parameters was determined. These parameters were included in a prototype of the automated design and in a production system developed by the authors.

Purpose This paper aims to study strength properties and accuracy of a new type of composites, in which matrix is manufactured additively, whereas infill is a polyurethane resin. The process of manufacturing these composites is invented and patented by authors. Design/methodology/approach The authors developed a method of manufacturing composites, which was then used to build samples for tensile and bending tests (according to ISO 572 and ISO 178 standards), as well as measurements of accuracy. Findings It was found that the method of composite manufacturing designed by the authors allows obtaining both stronger and cheaper parts in comparison with the traditional acrylonitrile butadiene styrene FDM parts. Research limitations/implications The research was limited to static tests only, and no dynamic tests were performed on the manufactured samples. The accuracy analysis is only a basic one. Practical implications Developed method allows to shorten the FDM process with simultaneous decrease of costs (in professional processes) and increase of strength of obtained products. Originality/value Application of composite materials presented in the paper will significantly expand possibilities of using FDM method to manufacture functional, strong parts able to carry higher loads. Application of different combinations of thermoplastic matrix materials with different resin infills will allow to control properties of obtained composites. The solution is currently subject of a patent.

The subject of the study are short sandwich beams with special structure of the core (honeycomb). The beam is made using additive manufacturing technology. The values of elastic modules vary along beam. The linear shear deformation theory – the “zig-zag” hypothesis is assumed for plane cross section. The analytical model of beam is based on this hypothesis. The deflection of beam is analytically calculated. Moreover, the deflection of beam is experimentally determined on a test stand. The results of these two methods are compared.

A new approach to product quality assessment taken by manufacturers integrates environmental aspects. Design for the environment, also referred to as ecodesign or sustainable design, is an innovative approach to the traditional design process. It focuses on compliance with ecological standards at an early stage of design in CAD 3D environment. In this paper, main objectives of the ecodesign process automation method based on a CAD 3D system are presented. The ecodesign process of a small household appliance is analyzed. The main features of a dedicated software application with a graphical interface, which runs independently of the CAD 3D system, are presented.

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 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.

The Virtual Reality technology is nowadays dynamically developed, thanks to appearance of low-cost devices and interest by large companies related to entertainment, communication and visualization. It is especially important in medicine, as it allows a much wider access to tools such as Virtual Reality Exposure Therapy. The paper presents possibilities of using low-cost VR devices in curing phobias by exposure to a stress-generating factor in an immersive virtual environment. Several use scenarios are presented for a simple application aimed at exposing a patient to fear of heights. A test group consisted of healthy individuals. To evaluate level of immersion and fear caused by the application, a heart rate monitor was used, to record heartbeat in real time.

In this paper, the application of multi-agent system to support decision-making process in design for recycling is presented. The design for recycling term is highlighted either as the design problem or from the point of view of regulations. The structure of agent system supporting the designer during the design process is showed. The basis of special kind of product model, that is the extension of standard 3D product model, called recycling-oriented product model, is described. The example results of analysis, based on real household appliance model, are presented.

The paper presents possibility of using a low-cost Fused Deposition Modelling process, realized by MakerBot Replicator 2X machine, in comparison with a professional one – realized by Dimension BST 1200 machine – to build tooling for an innovative training simulation, in accordance with Industry 4.0 guidelines. A physical object was manufactured and then tracked to manipulate in a virtual environment – it was a manual head used during the 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 main problem addressed in this paper is the use and evaluation of low-cost additive manufacturing (3D printing) techniques and CT images as tools for manufacture of usable and individualized, anatomically correct models, assisting surgeons in their daily work. The authors formulate own methodology of design and additive manufacturing of medical products on the basis of medical imaging data. A specific case was selected—a surgical lower jaw template for use in the middle of operation. Two Fused Deposition Modeling machines—professional and low-cost—were used to manufacture the same product, which was later evaluated, inspected for accuracy (by 3D scanning) and used during the surgery. By two 3D printing processes comparison it was found that the low cost comes at a price of lower accuracy and increased demand for process supervision. The authors obtained a fully usable medical product used during an actual reconstruction surgery. Partial clinical results are presented—use of 3D printed templates helped reduce surgery time and generally improved the patient recovery process.

The paper presents results of a pilot study using Augmented Reality techniques for learning and training of 3D printing process of Fused Deposition Modelling (FDM). The authors created a mobile, tablet-based Augmented Reality solution for learning of basic operations performed on a 3D printer during preparation and realization of a process of Fused Deposition Modelling. Then, two groups of novice students were tested for efficiency in realizing these processes: one group was taught using traditional learning method and the other—without any traditional training whatsoever, only basing on the Augmented Reality application for the process guidance (self-learning). The obtained process realization times were compared with reference times obtained by expert process engineers. The results are promising, but there is a high need of expert consulting for students using only the Augmented Reality.

The paper looks at the recycling-oriented analysis of selected household appliances in the CAD 3D environment, carried out on the basis of recycling-oriented product models, as a form of briefly-discussed eco-design. The recycling-oriented product model (RmW) and measures of recycling-oriented product assessment are explained. A software tool facilitating the creation of recycling-oriented models for selected products and calculation of assessment measures for the analysis are presented. Two examples of recycling-oriented product assessment with the use of the developed method and tools are shown.

The paper presents selection process of an appropriate engine to build a dedicated visual configuration system based on Virtual Reality, in cooperation with a city bus producer. The aim was to build a methodology of selection of such a software for a large visual configuration system and to validate it in practice, as there are no available software benchmarks in VR branch. To aid the decision making process, the Analytical Hierarchy Process method was proposed. Several most popular engines were taken into account. Final solution using the selected engine is also presented in the paper as a practical validation example.

The paper presents development process and studies of a digital, Virtual Reality based tool for assisting the decision making process in configuration of driver’s workplace in city buses. The development methodology is presented with an end result. The studies, carried out after implementation in an industrial company, were based on human-computer interaction tests and evaluation comparative to previous configuration methods available in the company. The assumed and presented methodology based on Knowledge-Based Engineering allowed to build and implement the tool very rapidly. The post-implementation studies allowed to find that employees of different divisions in a company perceive such a tool in very different ways, forming various directions of future development.