选区激光熔化直接成型个性化外科手术模板研究
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摘要
选区激光熔化(selective laser melting, SLM)快速成型是一种近十几年来发展起来的快速原型(RP-Rapid Prototyping)技术,它由于能直接成型金属件,成为国内外快速成型领域的一个重要研究方向。从选区激光熔化快速成型技术的现状和目前存在问题来看,成型设备、工艺的研发及应用领域的推广是研究热点。
本文主要研究了选区激光熔化快速成型技术在医学领域的应用,选用生物相容性好的316L不锈钢粉末材料进行了选区激光熔化成型实验研究,研究了工艺参数、能量输入、致密度、表面形貌之间的关系以及微观组织特征;医学临床应用流程和外科手术模板的设计、应用。论文的主要内容如下:
首先,回顾了快速成型技术在医学领域的应用现状,讨论了选区激光熔化快速成型技术的基本原理和研究现状,为本课题开展研究奠定了理论基础。
其次,针对选区激光熔化快速成型本身的特点,结合逆向工程技术,设计出了适用于医用个性化外科手术模板的一整套解决方案,提出了一种全数字化设计制造个性化金属质手术模板的方法,设计采用逆向工程结合正向建模实现,制造采用选区激光熔化快速成型技术实现。以一例骨科多发病例股骨头坏死为例探讨了针对SLM技术定制个性化手术模板的相关问题。
采用自行研制的光纤激光选区熔化快速成型设备,研究了选区激光熔化316L不锈钢粉末工艺参数、能量输入、致密度、表面形貌之间的关系,微观组织特征以及一些常见加工缺陷。分析了金属质手术模板的医学需求特点,从成型方式以及扫描策略两方面出发提出了可提高成型精确度,减少热变形和下表面加工缺陷的方案,扫描成型过程采用邻层互错、正交及分区扫描策略,成型出满足要求的模板。
文章最后选择具有代表性的外科手术为例,阐述了一种个性化外科手术的系统解决方案。只需要患者的CT/MRI图像便可以借助图像处理与设计软件直接进行术前的数字化手术规划、模拟以及设计对应的手术模板。手术结果表明:该解决方案简化了手术的操作,提高手术的准确性,为临床手术提供一种精确操作的方法,并为该技术今后在临床的应用推广提供了依据。
Selective laser melting (SLM) is a new technology of Rapid Prototyping (RP) developed in the last ten years. Metal parts can be directly made from powders by SLM, so it became one of the most promising technologies in the field of the advanced manufacturing. Current research of SLM involves the development of equipment, process optimization, and the experiment of application.
The research in this thesis was focusing on the medical application of selective laser melting. 316L stainless steel powder which has excellent biocompatibility is used in the experiments. The processing parameters, energy density, relative density, surface profile and characteristics of micro structures of 316 L stainless steel parts which processed by SLM was studied. The application of SLM in medical field especially in design and application of medical implants and surgery orienting model had beeb studied. The main achievements were as follows:
Firstly, the application of rapid prototyping in medical area was reviewed. The basic principles and the present research situation of selective laser melting were discussed. These contents stated above provided a theoretical basis to this study.
Secondly, a solution for medical application was proposed to manufacture customized surgery model by using selective laser melting combined with reverse engineering. A method of all-digital rapid design and manufacture of metal customized surgical model using reverse-engineering, forward-design and selective laser melting technologies was proposed. The process was demonstrated by taking surgical model of a typical common surgery case, osteonecrosis of the femoral head as examples.
An SLM system equipped with fiber laser was employed to study technical parameters, energy density, relative density, surface profile, some frequent processing defects and characteristics of micro structures of 316 L stainless steel parts. Based on analysis of surgical needs, methods to improve the model dimensional accuracy and scanning strategies such as offsetting the scanning lines in two adjacent layers, orthogonal scanning and partition scanning to decreased thermal deformation and undersurface process defects had been figured out. Finally, surgical models which can meet the application requirements was designed and manufactured successfully.
Finally, some typical surgery cases were studied, and a systematic solution of all-digital customized surgery was proposed. From CT/MRI image data of a patient preoperative planning, surgical simulation and design the customized surgery model can be completed. The technology of direct manufacturing of surgery orienting model by selective laser melting shows obvious superiority with high speed, precise profile and good accuracy in size comparing with the traditional ones ,and will build a foundation for more clinical applications in the future.
本文主要研究了选区激光熔化快速成型技术在医学领域的应用,选用生物相容性好的316L不锈钢粉末材料进行了选区激光熔化成型实验研究,研究了工艺参数、能量输入、致密度、表面形貌之间的关系以及微观组织特征;医学临床应用流程和外科手术模板的设计、应用。论文的主要内容如下:
首先,回顾了快速成型技术在医学领域的应用现状,讨论了选区激光熔化快速成型技术的基本原理和研究现状,为本课题开展研究奠定了理论基础。
其次,针对选区激光熔化快速成型本身的特点,结合逆向工程技术,设计出了适用于医用个性化外科手术模板的一整套解决方案,提出了一种全数字化设计制造个性化金属质手术模板的方法,设计采用逆向工程结合正向建模实现,制造采用选区激光熔化快速成型技术实现。以一例骨科多发病例股骨头坏死为例探讨了针对SLM技术定制个性化手术模板的相关问题。
采用自行研制的光纤激光选区熔化快速成型设备,研究了选区激光熔化316L不锈钢粉末工艺参数、能量输入、致密度、表面形貌之间的关系,微观组织特征以及一些常见加工缺陷。分析了金属质手术模板的医学需求特点,从成型方式以及扫描策略两方面出发提出了可提高成型精确度,减少热变形和下表面加工缺陷的方案,扫描成型过程采用邻层互错、正交及分区扫描策略,成型出满足要求的模板。
文章最后选择具有代表性的外科手术为例,阐述了一种个性化外科手术的系统解决方案。只需要患者的CT/MRI图像便可以借助图像处理与设计软件直接进行术前的数字化手术规划、模拟以及设计对应的手术模板。手术结果表明:该解决方案简化了手术的操作,提高手术的准确性,为临床手术提供一种精确操作的方法,并为该技术今后在临床的应用推广提供了依据。
Selective laser melting (SLM) is a new technology of Rapid Prototyping (RP) developed in the last ten years. Metal parts can be directly made from powders by SLM, so it became one of the most promising technologies in the field of the advanced manufacturing. Current research of SLM involves the development of equipment, process optimization, and the experiment of application.
The research in this thesis was focusing on the medical application of selective laser melting. 316L stainless steel powder which has excellent biocompatibility is used in the experiments. The processing parameters, energy density, relative density, surface profile and characteristics of micro structures of 316 L stainless steel parts which processed by SLM was studied. The application of SLM in medical field especially in design and application of medical implants and surgery orienting model had beeb studied. The main achievements were as follows:
Firstly, the application of rapid prototyping in medical area was reviewed. The basic principles and the present research situation of selective laser melting were discussed. These contents stated above provided a theoretical basis to this study.
Secondly, a solution for medical application was proposed to manufacture customized surgery model by using selective laser melting combined with reverse engineering. A method of all-digital rapid design and manufacture of metal customized surgical model using reverse-engineering, forward-design and selective laser melting technologies was proposed. The process was demonstrated by taking surgical model of a typical common surgery case, osteonecrosis of the femoral head as examples.
An SLM system equipped with fiber laser was employed to study technical parameters, energy density, relative density, surface profile, some frequent processing defects and characteristics of micro structures of 316 L stainless steel parts. Based on analysis of surgical needs, methods to improve the model dimensional accuracy and scanning strategies such as offsetting the scanning lines in two adjacent layers, orthogonal scanning and partition scanning to decreased thermal deformation and undersurface process defects had been figured out. Finally, surgical models which can meet the application requirements was designed and manufactured successfully.
Finally, some typical surgery cases were studied, and a systematic solution of all-digital customized surgery was proposed. From CT/MRI image data of a patient preoperative planning, surgical simulation and design the customized surgery model can be completed. The technology of direct manufacturing of surgery orienting model by selective laser melting shows obvious superiority with high speed, precise profile and good accuracy in size comparing with the traditional ones ,and will build a foundation for more clinical applications in the future.
引文
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[2]Garrett W, Abbey PA, Christensen RW: Temporomandibular joint reconstruction with a custom total temporomandibular joint prosthesis: Use in the multiply-operated patient. Plast. Reconstr Surg Surg Technol Int, 1997,VI:347-354
[3]孟娟,潘晓雯,朱家瑞等.单光子发射型计算机断层显像与脑CT及MRI对持续植物状态患者脑血流灌注的观察[J].中国临床康复,2004(4):752-754
[4]刘光富,张曙,黄仲明.用快速成型技术构建医学模型[J].制造业自动化,2002(23):6-12
[5]何兴容,杨永强,王迪等.选区激光熔化直接成型个性化牙冠牙桥研究[J].激光技术,2010,34(1):1-4
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