Single point incremental forming of a facial implant

Background: The investigation draws from the fundamentals of the mechanical behaviour of titanium grade 2 to the design and fabrication of facial implants by means of single point incremental forming. Objectives: To provide knowledge on the capabilities and limitations of a new manufacturing technology to fabricate low-cost, patient-specific medical implants. Study design: Rapid fabrication of a simplified model of a facial implant. Methods: Circle grid analysis and its graphical representation in the fracture forming limit diagram combined with finite element modelling are utilized to identify the failure limits and to assist the overall design of the facial implants. Results: Fabrication of facial implants without and with failure by cracking due to excessive thinning of the sheet from where the implant is to be cut. Conclusions: Identification of the major operative parameters that influence fabrication of sound facial implants by means of single point incremental forming. Clinical relevance Reduce the gap between production engineers and the medical community by presenting a state-of-the-art manufacturing technology to produce low-cost, patient-specific medical implants.