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This manuscript presents a simplified approach to adhesive joints calculation. Aviation and space rocket engineering constructions joints deals with coaxial cylindrical pipes that can be connected by adhesive with advantages in terms of tightness, aerodynamic efficiency, manufacturability, low weight. Glue joints are, therefore, considered and simplified in this article by the analytical calculation of the shape functions for a macro-element applied to the Volkersen’s theory. The mathematical solution makes possible to calculate the explicit form of the stiffness matrix of the macro-element. The analysis proposed shows the perfect matching of the solution for a single element under classical mechanical loads.

Many industrial technologies are developed to optimize products and bring innovation. In particular, the automotive sector is renewing itself according to the rules of green energy and consumption. This huge change requires a reinterpretation of the models on the market updating them to the present and the future needs of automotive industry. In this paper the best compromise between innovation and tradition is found for the Ford brand that has not yet presented electric cars in the sedan segment. Following the SDE method enriched with Quality Function Deployment (QFD), Benchmarking (BM) and Top Flop Analysis (TPA), it is possible to carry out an innovative project. All these technologies must, however, be ordered according to a specific product allowing the best result for the design process. It is therefore necessary identifying the most common stylistic trends in order to draw the external styling of the vehicle using virtual prototyping techniques. To achieve an innovative result, Augmented Reality (AR) is considered to complete the method substituting the static and expensive procedure of making maquettes.

Additive manufacturing processes have evolved considerably in the past years, growing into a wide range of products through the use of different materials depending on its application sectors. Nevertheless, the fused deposition modelling (FDM) technique has proven to be an economically feasible process turning additive manufacture technologies from consumer production into a mainstream manufacturing technique. Current advances in the finite element method (FEM) and the computer-aided engineering (CAE) technology are unable to study three-dimensional (3D) printed models, since the final result is highly dependent on processing and environment parameters. Because of that, an in-depth understanding of the printed geometrical mesostructure is needed to extend FEM applications. This study aims to generate a homogeneous structural element that accurately represents the behavior of FDM-processed materials, by means of a representative volume element (RVE). The homogenization summarizes the main mechanical characteristics of the actual 3D printed structure, opening new analysis and optimization procedures. Moreover, the linear RVE results can be used to further analyze the in-deep behavior of the FDM unit cell. Therefore, industries could perform a feasible engineering analysis of the final printed elements, allowing the FDM technology to become a mainstream, low-cost manufacturing process in the near future.

The design of an E segment, executive, midsize sedan car was chosen to fill a gap in the market of the Ford brand and to achieve the goal of innovation looking towards the future. Ford has not owned an E-segment flagship sports sedan for years, since the historic 1960s Falcon. Starting from the latter assumption and considering that the major car manufacturers are currently investing heavily in E-segment cars, it is important to design a new model, which has been called the Eagle. This model proposed here is to fill the gap between Ford and other companies that are already producing sport cars for the electric sector and to complete Ford’s proposal. The presented methodology is based on SDE, on which many design tools are implemented, such as Quality Function Deployment (QFD), Benchmarking (BM), and Top Flop Analysis (TPA). A market analysis follows in order to identify the major competitors and their key characteristics considering style and technology. The results are used to design an innovative car. Based on the most developed stylistic trends, the vehicle is first sketched and then drawn in the 2D and 3D environments for prototyping. This result leads to the possibility of 3D printing the actual model as a maquette using the Fused Deposition Modelling (FDM) technology and testing it in different configurations in Augmented Reality (AR). These two final applications unveil the possibilities of Industry 4.0 as enrichment for SDE and in general rapid prototyping.

Technology evolution and wide research attention on 3D printing efficiency and processes have given the prompt need to reach an understanding about each technique’s prowess to deliver superior quality levels whilst showing an economical and process viability to become mainstream. Studies in the field have struggled to predict the singularities that arise during most Fused Deposition Modeling (FDM) practices, therefore, diverse individual description of the parameters have been performed, but a relationship study between them has not yet assessed. The proposed study lays the main defects caused by a selection of printing parameters which might vary layer slicing, then influencing the defect rate. Subsequently, the chosen technique for optimization is presented, with evidence of its application viability that suggests that a quality advance would be gathered with such. The results would help in making the FDM process become a reliable process that could also be used for industry manufacturing besides prototyping purposes.

Three-dimensional printed custom cutting guides (CCGs) are becoming more and more investigated in medical literature, as a patient-specific approach is often desired and very much needed in today’s surgical practice. Three-dimensional printing applications and computer-aided surgical simulations (CASS) allow for meticulous preoperatory planning and substantial reductions of operating time and risk of human error. However, several limitations seem to slow the large-scale adoption of 3D printed CCGs. CAD designing and 3D printing skills are inevitably needed to develop workflow and address the study, therefore, hospitals are pushed to include third-party collaboration, from highly specialized medical centers to industrial engineering companies, thus increasing the time and cost of labor. The aim of this study was to move towards the feasibility of an in-house, low-cost CCG 3D printing methodology for pediatric orthopedic (PO) surgery. The prototype of a femoral cutting guide was developed for its application at the IOR—Rizzoli Orthopedic Institute of Bologna. The element was printed with an entry-level 3D printer with a high-temperature PLA fiber, whose thermomechanical properties can withstand common steam heat sterilization without bending or losing the original geometry. This methodology allowed for extensive preoperatory planning that would likewise reduce the overall surgery time, whilst reducing the risks related to the intervention.

The study of CAD (computer aided design) modeling, design and manufacturing techniques has undergone a rapid growth over the past decades. In medicine, this development mainly concerned the dental and maxillofacial sectors. Significant progress has also been made in orthopedics with pre-operative CAD simulations, printing of bone models and production of patient-specific instruments. However, the traditional procedure that formulates the surgical plan based exclusively on two-dimensional images and interventions performed without the aid of specific instruments for the patient and is currently the most used surgical technique. The production of custom-made tools for the patient, in fact, is often expensive and its use is limited to a few hospitals. The purpose of this study is to show an innovative and cost-effective procedure aimed at prototyping a custom-made surgical guide for address the cubitus varus deformity on a pediatric patient. The cutting guides were obtained through an additive manufacturing process that starts from the 3D digital model of the patient’s bone and allows to design specific models using Creo Parametric. The result is a tool that adheres perfectly to the patient’s bone and guides the surgeon during the osteotomy procedure. The low cost of the methodology described makes it worth noticing by any health institution.

This work describes a Mixed Reality application useful to modify and cut virtual objects. A digital simulation of surgical operations is presented. Following this approach, surgeons can test all the designed solutions of the preoperative stage in a Mixed Reality environment. High precision in surgery applications can be achieved thanks to the new methodology. The presented solution is hands free and does not need the use of a mouse or computer&rsquo, s keyboard: it is based on HoloLens, Leap Motion device and Unity. A new cutting algorithm has been developed in order to handle multiple objects and speed up the cut with complex meshes and preserve geometry quality. A case study presents the cut of several bones in order to simulate surgeon&rsquo, s operations. A reduction in cut time compared to the original method is noticed, together with a high flexibility of the tool and a good fidelity of the geometry. Moreover, all the object fragments generated from the algorithm are available for manipulation and new cuts.

&ldquo, Innovation activities&rdquo, means all the scientific, technological, organizational, financial and commercial steps aimed at implementing innovation. Some innovation activities are themselves innovative, others are not new, but they are necessary for the implementation of innovation, such as Research and Development not linked to a specific innovation. Innovation has a close reference to the economic market, that is to say with the users of the innovated product: if these are not sufficiently developed they are not able to understand it and appreciate it. Innovation, making the process better, generates greater competitiveness: it is the dream of something better that translates into general well-being. This work presents an innovative hybrid car&rsquo, s design, belonging to the E-segment. The choice of this segment is already innovative in its nature, as despite being currently in strong development, hybrid and electric engines are still little used for large sedans. The method we present in this paper for the car design is also innovative and is called Design for Six Sigma. It is a method used to develop new products, through the determination of customer and market needs and the transformation of these requests into the product generated.

In this paper, we present a solution for the photorealistic ambient light render of holograms into dynamic real scenes, in augmented reality applications. Based on Microsoft HoloLens, we achieved this result with an Image Base Lighting (IBL) approach. The real-time image capturing that has been designed is able to automatically locate and position directional lights providing the right illumination to the holograms. We also implemented a negative &ldquo, shadow drawing&rdquo, shader that contributes to the final photorealistic and immersive effect of holograms in real life. The main focus of this research was to achieve a superior photorealism through the combination of real-time lights placement and negative &ldquo, shader. The solution was evaluated in various Augmented Reality case studies, from classical ones (using Vuforia Toolkit) to innovative applications (using HoloLens).

This experimental study defines the usage of a computer-aided surgical simulation process that is effective, safe, user-friendly, and low-cost, that achieves a detailed and realistic representation of the anatomical region of interest. The chosen tools for this purpose are state-of-the-art Computer Aided Design (CAD) software for mechanical design, and are the fundamental application dedicated to parametric modeling. These tools support different work environments, each one is for a specific type of modeling, and they allow the simulation of surgery. The result will be a faithful representation of the anatomical part both before and after the surgical procedure, screening all the intermediate phases. The doctor will assess different lines of action according to the results, then he will communicate them to the engineer who, consequently, will correct the antisymmetric issue and regenerate the model. Exact measurements of the mutual positions of the various components, skeletal and synthetic, can be achieved; all the osteosynthesis tools, necessary for the surgeon, can be included in the project according to different types of fracture to perfectly match the morphology of the bone to be treated. The method has been tested on seven clinical cases of different complexity and nature and the results of the simulations have been found to be of great effectiveness in the phase of diagnosis and of preoperative planning for the doctors and surgeons; therefore, allowing a lower risk medical operation with a better outcome. This work delivers experimental results in line with theoretical research findings in detail; moreover, full experimental and/or methodical details are provided, so that outcomes could be obtained.

Augmented Reality (AR) is worldwide recognized as one of the leading technologies of the 21st century and one of the pillars of the new industrial revolution envisaged by the Industry 4.0 international program. Several papers describe, in detail, specific applications of Augmented Reality developed to test its potentiality in a variety of fields. However, there is a lack of sources detailing the current limits of this technology in the event of its introduction in a real working environment where everyday tasks could be carried out by operators using an AR-based approach. A literature analysis to detect AR strength and weakness has been carried out, and a set of case studies has been implemented by authors to find the limits of current AR technologies in industrial applications outside the laboratory-protected environment. The outcome of this paper is that, even though Augmented Reality is a well-consolidated computer graphic technique in research applications, several improvements both from a software and hardware point of view should be introduced before its introduction in industrial operations. The originality of this paper lies in the detection of guidelines to improve the Augmented Reality potentialities in factories and industries.

This paper presents the application of a low-cost 3D printing technology in pre-operative planning and intra-operative decision-making. Starting from Computed Tomography (CT) scans, we were able to reconstruct a 3D model of the area of interest with a very simple and rapid workflow, using open-source software and an entry level 3D printer. The use of High Temperature Poly-Lactic Acid (HTPLA) by ProtoPasta allowed fabricating sterilizable models, which could be used within the surgical field. We believe that our method is an appealing alternative to high-end commercial products, being superior for cost and speed of production. It could be advantageous especially for small and less affluent hospitals that could produce customized sterilizable tools with little investment and high versatility.

This paper presents a a novel alghorithm of diagnosis and treatment of rigid flatfoot due to tarsal coalition. It introduces a workflow based on 3D printed models, that ensures more efficiency, not only by reducing costs and time, but also by improving procedures in the preoperative clinical phase. Since this paper concerns the development of a new methodology that integrates both engineering and medical fields, it highlights symmetry. An economic comparison is made between the traditional method and the innovative one, the results demonstrate a reduction in costs with the latter. The current, traditional method faces critical issues in diagnosing the pathologies of a limb (such as the foot) and taking decisions for further treatment of the same limb. The proposed alternative methodology thus uses new technologies that are part of the traditional workflow, only replacing the most obsolete ones. In fact, it is increasingly becoming necessary to introduce new technologies in orthopedics, as in other areas of medicine, to offer improved healthcare services for patients. Similar clinical treatments can be performed using the aforementioned technologies, offering greater effectiveness, more simplicity of approach, shorter times, and lower costs. An important technology that fits into this proposed methodology is 3D printing.