An Innovative Method to Analyse the Geometrical Accuracy of Ti6Al4V Octet-Truss Lattice Structures.

Metal lattice structures manufactured utilising additive techniques are attracting increasing attention thanks to the high structural efficiency they can offer. Although many studies exist on the characterisation of massive parts in Ti6Al4V processed by Electron Beam Melting (EBM), several investigations are necessary to characterise the Ti6Al4V lattice structures made by the EBM process. The objective of this paper is to develop a measurement method to assess the dimensional accuracy of Ti6Al4V octet truss lattice structures manufactured by EBM technology. Beam specimens with a 2 mm diameter and different growth orientations with respect to the build direction were analysed. The geometry differences between the designed and the manufactured beam specimens were highlighted. Two effects were identified: (i) The EBM-manufactured beams are generally thinner than the designed ones, and (ii) the shape of the section was found to be almost circular for the beam specimens oriented at 45° and 90°; on the contrary, the section of the horizontal beam (0°) cannot be considered circular.

Simple quality assurance based on filtered back projection for geometrical/irradiation accuracy in single-isocenter multiple-target stereotactic radiotherapy.

In single-isocenter multiple-target stereotactic radiotherapy (SIMT-SRT), it is difficult to evaluate both the geometrical accuracy and absorbed dose measurement when irradiating off-isocenter targets. This study aimed to develop a simple quality assurance (QA) method to evaluate off-isocenter irradiation position accuracy in SIMT-SRT and compare its feasibility with that of a commercial device. First, we created two types of inserts and metallic balls with a diameter of 5 mm to be inserted into a commercially available phantom (SIMT phantom). Second, we developed a dedicated analysis software using Python for the Winston-Lutz test (WLT). Third, an image processing software, including the filtered back-projection algorithm, was developed to analyze the images obtained using an electronic portal imaging device (EPID). Fourth, the feasibility of our method was evaluated by comparing it with the results of WLT using two commercially available phantoms: WL-QA and MultiMet-WL cubes. Notably, 92% of the results in one-dimensional deviations were within 0.26 mm (EPID pixel width). The correlation coefficients were 0.52, 0.92, and 0.96 in the left-right, superior-inferior, and anterior-posterior directions, respectively. In the WLT, a maximum two-dimensional deviation of 0.70 mm was detected in our method, while the deviation in the other method was within 0.5 mm. The advantage of our method is that it can evaluate the geometrical accuracy at any gantry angle during dynamic rotation irradiation using a filtered back-projection algorithm, even if the target is located off the isocenter. Our method can perform WLT at arbitrary positions and is suitable for the QA of dynamic rotation irradiation using an EPID.

Mechanical and microstructural characterization of titanium gr.5 parts produced by different manufacturing routes.

Since a few decades, the aircraft industry has shifted its preference for metal parts to titanium and its alloys, such as the high-strength titanium grade 5 alloy. Because of titanium grade 5 limited formability at ambient temperature, forming operations on this material requires high temperatures. In these conditions, a peculiar microstructure evolves as a result of the heating and deformation cycles, which has a significant impact on formability and product quality. On the other hand, additive manufacturing technologies, such as selective laser melting and electron beam melting, are increasingly being used and are replacing more traditional approaches such as machining and forging. Fundamental part characteristics such as mechanical and microstructural properties, geometric accuracy, and surface quality strongly depend on the selection of the manufacturing method. The authors of this paper seek to identify the strengths and limitations imposed by the intrinsic characteristics of different manufacturing alternatives for the production of parts of aeronautical significance, providing guidelines for the choice of the most appropriate manufacturing route for a given application and part design.

Influence of Implant Impression Methods, Polymer Materials, and Implant Angulation on the Accuracy of Dental Models.

The paper presents the influence of impression methods, polymer materials, and implant angulation on the accuracy of the definitive working model for the production of implant-supported dental restorations, based on the analysis of results obtained using different impression methods, materials, and parallel and angulated implants. The study findings indicate that all aforementioned factors impact the accuracy of the definitive working model. Specifically, 20° implant angulation in relation to the vertical plane has a greater impact on the impression accuracy compared to parallel implants. The open and splint method in combination with addition silicone, as well as the splint method and polyether combination yielded more accurate results when using implants under 20° angulation compared to other method and material combinations. The splint method in combination with addition silicone resulted in the smallest mean deviations from the center of the parallel implant base compared to other combinations of methods and materials. Analysis results further revealed statistically significant differences in the measured indicators across impression methods, implants, and polymer materials.

A Comparison of the Geometrical Accuracy of Thin-Walled Elements Made of Different Aluminum Alloys.

In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural elements are being used in the form of monolithic elements, which are replacing the assemblies of parts joined by, for example, riveting. These structures often have a complex, thin-walled geometry with deep pockets. This paper attempts to assess the accuracy of manufacturing thin-walled elements, in the shape of walls with different geometries, made of various aluminum alloys. Machining tests were conducted at different cutting speeds, which allowed comparisons of the geometric accuracy of parts manufactured under conventional and high-speed cutting conditions. Based on the result obtained, it was found that the elements made of EN AW-7075 T651 alloy underwent the greatest deformations during machining in comparison to other two materials (EN AW-6082 T651 and EN AC-43000). An increase in the geometrical accuracy of the manufactured elements was also observed with the increase in the cutting speed for the HSC range. Hence, to minimize the postmachining deformation of thin-walled elements, the use of high-speed cutting is justified.

Study on Geometry, Dimensional Accuracy and Structure of Parts Produced by Multi Jet Fusion.

Multi Jet Fusion (MJF) is one of the newest additive manufacturing technologies for polymer powders, introduced in recent years. This fully industrial technology is gaining big interest as it allows fast, layer-by-layer, printing process, short production cycle, and very high printing resolution. In this paper, twelve thin-walled, spherical PA12 prints were studied in terms of geometry, dimensional accuracy, and fracture surface characteristics. The various characteristic features for MJF prints were observed here for parts produced according to four various print orientations and having different thicknesses, i.e., 1, 2 or 3 mm. The study showed that MJF technology can print such difficult shapes. However, the set of parameters allowing producing parts with highest geometrical and dimensional accuracy causes at the same time some microstructural issues, like great interlayer porosity or high number of non-processed powder particles embedded in the print structure.

Geometrical imaging accuracy, image quality and plan quality for prostate cancer treatments on a 1.5 T MRLinac in patients with a unilateral hip implant.

Purpose.To assess the feasibility of prostate cancer radiotherapy for patients with a hip implant on an 1.5 T MRI-Linac (MRL) in terms of geometrical image accuracy, image quality, and plan quality.Methods.Pretreatment MRI images on a 1.5 T MRL and 3 T MRI consisting of a T2-weighted 3D delineation scan and main magnetic field homogeneity (B0) scan were performed in six patients with a unilateral hip implant. System specific geometrical errors due to gradient nonlinearity were determined for the MRL. Within the prostate and skin contour,B0inhomogeneity, gradient nonlinearity error and the total geometrical error (vector summation of the prior two) was determined. Image quality was determined by visually scoring the extent of implant-born image artifacts. A treatment planning study was performed on five patients to quantify the impact of the implant on plan quality, in which conventional MRL IMRT plans were created, as well as plans which avoid radiation through the left or right femur.Results.The total maximum geometrical error in the prostate was <1 mm and the skin contour <1.7 mm; in all cases the machine-specific gradient error was most dominant. TheB0error for the MRlinac MRI could partly be predicted based on the pre-treatment 3 T scan. Image quality for all patients was sufficient at 1.5 T MRL. Plan comparison showed that, even with avoidance of the hips, in all cases sufficient target coverage could be obtained with similar D1cc and D5cc to rectum and bladder, while V28Gy was slightly poorer in only the rectum for femur avoidance.Conclusion.We showed that geometrical accuracy, image quality and plan quality for six prostate patients with a hip implant or hip fixation treated on a 1.5 T MRL did not show relevant deterioration for the used image settings, which allowed safe treatment.

Analysis of Modern Optical Inspection Systems for Parts Manufactured by Selective Laser Melting.

Metal additive manufacturing (AM) allows obtaining functional parts with the possibility of optimizing them topologically without affecting system performance. This is of great interest for sectors such as aerospace, automotive, and medical-surgical. However, from a metrological point of view, the high requirements applied in these sectors constitute a challenge for inspecting these types of parts. Non-contact inspection has gained great relevance due to the rapid verification of AM parts. Optical measurement systems (OMSs) are being increasingly adopted for geometric dimensioning and tolerancing (GD&T) verification within the context of Industry 4.0. In this paper, the suitability (advantages and limitations) of five different OMSs (based on laser triangulation, conoscopic holography, and structured light techniques) for GD&T verification of parts manufactured by selective laser melting (SLM) is analyzed. For this purpose, a specific testing part was designed and SLM-manufactured in 17-4PH stainless steel. Once the part was measured by contact (obtaining the reference GD&T values), it was optically measured. The scanning results allow comparing the OMSs in terms of their inspection speed as well as dimensional and geometrical accuracy. As a result, two portable systems (handheld laser triangulation and structured blue-light scanners) were identified as the most accurate optical techniques for scanning SLM parts.

Investigation of Production Limits in Manufacturing Microstructured Surfaces Using Micro Coining.

The application of microstructured surfaces is one possible method to reduce friction in lubricated contacts between components with relative movement. Due to this, the energy efficiency and the occurring wear during the operating time of the final products could be decreased. To manufacture structured surfaces economically, a micro coining process was analyzed within this study. This process offers the potential for integration into the established manufacturing processes of different final products, such as tappets used in a valve train. Thus, large-scale production is enabled. To detect the manufacturing limits of the micro coining process, the manufacturing of the coining tools as well as the coining process needs to be investigated. Within this study, the achievable accuracy and the failure of cuboid and cylindrical microstructure elements with selected dimensions were analyzed. For both types of microstructures, the minimal lateral dimensions were detected. Besides the achievable accuracy, correlations between different geometrical dimensions of the micro elements are presented. Additionally, the aspect ratio is detected as the main cause of failure for the micro coining process. In general, the suitability of a coining process for manufacturing microstructured surfaces is proven.

Diffusion weighted MRI in head-and-neck cancer: geometrical accuracy.

INTRODUCTION: The aim of this study is to assess the geometric accuracy of diffusion weighted (DW)-MRI by quantification of geometric distortions in the gross tumor volume (GTV) in head and neck (HN) cancer. MATERIALS & METHODS: A retrospective analysis was performed on the data of 23 patients (with 24 lesions). For these patients, magnetic field maps and DW-MRI were acquired. The magnetic field maps were converted to voxel displacement maps. GTV delineations were transferred onto these voxel displacement maps and the voxel shifts in the GTV were analyzed. RESULTS: The median shift was 3.2mm and the maximal posterior and anterior shifts were up to 15.0 and 26.0mm respectively. The range of shifts varied from 11.8 to 25.6mm. The percentage of GTV voxels that showed a shift of at least 6mm was found to be 23.2%. CONCLUSIONS: Current DW-MRI images of HN tumors show severe distortions up to centimeters, which restrict the use of DW-MRI scans for GTV definition in RT treatment planning.