COURSE PROJECT (30%)

2022-2023

Course: Mechanical Behavior of Materials

ME569
Semester: Fall 2022

2022 -2023

Design of 3D-printed auxetic-structured intervertebral

disc implant
Dr. Fethi Abbassi
Contents
I. Introduction ............................................................................................................................. 3

II. Project Description .................................................................................................................. 4

III. Learning Outcomes.................................................................................................................. 5

IV. Project Files ............................................................................................................................. 5

V. Project Summary (Scenario) .................................................................................................... 6

VI. Deliverables & Project Management ....................................................................................... 6

VII. Turnitin .................................................................................................................................... 6

VIII. APA Style .............................................................................................................................. 7

IX. Marking Scheme ...................................................................................................................... 7

I. Plagiarism ................................................................................................................................ 9

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I. Introduction

Projects for engineering students give an edge over the race of recruitment to work hard to ensure
a good career. In spite of employment practices in recent times. Engineering projects help students
to learn and acquire practical knowledge. Despite of theory concept they acquire, various industries
also need to know their capacity to complete projects using their specific initiatives. Thus, we
recommend students to realize engineering projects in their four years of engineering and try to
present as many white papers as possible. Students who give importance to their course projects
are expected to learn how to:
• Work in teams including multidisciplinary teams
• Build a major design experience based on the knowledge and skills acquired in the course
work
• Build a major design experience incorporates appropriate engineering standards and
multiple realistic constraints
• Apply both analysis and synthesis in the engineering design process, resulting in designs
that meet the desired needs
In the design process, both creativity and criticism are essential. The followings are the seven steps
that students should consider while designing their projects:
• Recognition of the need and identifying opportunities: Every project begins with
recognition that needs improvement. These needs may be obvious or hidden to be revealed
by investigation, surveys or research.
• Definition of the design problem: It is a major task requires gathering information about
the problem.
• Definition of the design criteria and constraints: While the problem is being defined, the
design criteria and constraints must be defined
a. Design criteria are performance standards to be met by the design
b. Design constraints are limitations placed on the designer, the final design or
manufacturing process. Examples of possible constraints include accessibility,
aesthetics, codes, constructability, cost, ergonomics, extensibility, functionality,
interoperability, legal considerations, maintainability, manufacturability,
marketability, policy, regulations, schedule, standards, sustainability, or usability.
c. Risk analysis
• The design loop: design is a repetitive process of:
a. Synthesis (Brainstorming - Generating new ideas)
b. Analysis (Breaking ideas – find expected results)
c. Decision-making (Deciding the best alternative)
• Optimization: Design team must ask themselves if it is the optimum design. Optimum is
the best design that can be achieved at reasonable cost. The proposed design is judged
against the design criteria
Evaluation: Design team should hold a design review to approve drawings and specifications
before they are released. If an optimum design cannot be achieved, the design team might revise
the problem definition, the design criteria or the constraints in order to achieve the optimal
solution or prototype.

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 Group Size: 2-3 students

II. Project Description

Over the years, intervertebral fusion cages (IFC), also known as "interbody cages", "disc cages",
or "cages", are manufactured to be implanted between vertebrae, for restoring and recovering the
disc space by replacing the damaged or deformed intervertebral disc.
Additive manufacturing (AM), which is a layer-by-layer process is being used for the development
of spinal implants for both conventional off-the-shelf as well as custom implants. Using AM, it is
possible to manufacture porous titanium cages having better loadbearing characteristics, less
micromotion, high compressive strength, osteoconductivity, and bone-bonding ability, eliminating
the need for autografting, and possessing interconnected pores for easy fluid flow.
The project has been structured into four main themes:
(1) Knowledge and education.
(2) Design and simulation.
(3) Materials selection and fabrication (AM).
(4) Cost estimation; These themes should be outlined in more detail with some examples.

Porous medical device fabricated by additive manufacturing (AM).

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 Project deliverable 1- description
The project deliverable 1 is a literature review about:
• Biomedical Application
• 3D printing and Additive manufacturing technics
• 3d printed structures behavior/3D-printed auxetic-structured parts
• Use of Additive manufacturing for biomechanical applications.
• Available design of intervertebral disc and the applied mechanical load.
• Intervertebral disc prosthesis and used materials
Project Deliverable 2

1. Provide a professional report including:

• A survey on intervertebral disc prosthesis and used materials
• Compare between different available designs (advantages and disadvantages).
2. Select geometry and dimensions of used design to be redesigned used advanced technics
such auxetic structures.
3. Design the 3D frame using CAD software (Solid works or other)
4. Select the most appropriate material for this application and justify your choice (may you
can use a comparative study)
5. Perform a survey on the different static load cases and perform a numerical modeling.
6. Estimate the cost of final product based on manufacturing process, materials, design, …
Project Deliverable 3

Project presentation (PowerPoint)

III. Learning Outcomes

• ABET ( A-F), refer to the syllabus for the details

• Basic Mechanics I Learning outcomes, refer to the syllabus for the details
Specific Learning Outcomes:
• Ability to apply theoretical knowledge in ‘real work’ project
• Ability to create mathematical models of real life situations and apply reasonable
assumptions to come up with an acceptable solution.
• Ability to present findings in clear and concise manner
• Ability to draw meaningful conclusions

IV. Project Files

Files associated with the project are posted on Moodle with CSE Edu pack tutorial videos
CES EduPack tutorial materials: https://www.youtube.com/watch?v=VZ8CB4vlbr0
https://www.youtube.com/playlist?list=PL86K9juZhi9TQ6qd2RxUMYXsMSAusWEnH

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 https://www.sciencedirect.com/science/article/pii/S2452199X22002675

V. Project Summary (Scenario)

Imagine that you are a mechanical engineer working for a biomedical company. Your manager
has given you the task of designing and selecting the materials for a disc based on customer and
medical specifications. As long as all conditions are satisfied, the manufacturing specifications are
followed, and the cost is kept as cheap as possible, you are free to design the prosthesis however
you see fit.

VI. Deliverables & Project Management

Deliverable Deadline Method of Delivery Grade

Allocated
Groups of students should be formed and
names submitted to the instructor. Upload report on
A technical report including abstract, and
D1 W9 Moodle on the specified 10%
answer to the related questions should be
link
submitted.

Upload update report

A technical report explaining the
on Moodle on the
D2 procedure and solution to D2 should be W15 12%
specified link (Turnitin
submitted.
submission)

PowerPoint
Final Presentation (PPT to be upload on W15 presentation uploaded
D3 8%
Moodle) on Moodle and
presented in the class

Total 25%

At least 2 faculty/students meetings must take place during the semester. The meetings can be
used to receive/evaluate deliverables or to provide feedback on deliverables.

VII. Turnitin

Turnitin is a web-based solution that lets AUM faculty and AUM students check written work
for improper citation or misappropriated content. You may be assigned a username and a
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 password to be able to upload your assignments online, when and if requested. If you face any
technical problem, please contact IT at AUM.

VIII. APA Style

AUM adopts the APA writing style for all its academic programs. AUM students need to use this
style for their assignments. The following web site is of value for students:
http://owl.english.purdue.edu/owl/resource/560/01/. Students are also encouraged to visit the
AUM Writing Lab to receive help and guidance on all APA-related questions.

IX. Marking Scheme

Deliverable 100% 85% 75% 60%

Well written initial Initial report includes Initial report lacks Initial report lacks
report includes all all items but lacks clarity and missing clarity and missing
D1 elements mentioned clarity one element two items
in D1 above

100% 85% 75% 60%

Updated D1 report Updated report Updated report Updated report
includes - includes - includes - includes -
very neat design and very neat design and neat design and acceptable design
D2 (refer to - lowest cost - 2nd lowest cost - 3rd lowest cost and -
table in last compared to other compared to other compared to other 4th lowest cost
page) class sections class sections class sections compared to other
-Accurate hand -Accurate hand -Accurate hand class sections
calculations calculations. calculations -hand calculations
- Well written report - satisfactorily written - Poorly written with some mistake
includes all the report includes all the report includes some - Very weak report
required elements elements of the elements
100% 85% 75% 60%
D3 excellent good presentation acceptable Weak presentation
presentation presentation

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Performance Beginning Developing Proficient Exemplary
Indicator
1. Structure: The report is Evident effort The report The report follows
poorly of report follows a formal a formal structure
5%
structured with structure. structure and and appropriate
little However, little appropriate to to the topic
organization attention is the topic.
given to However,
formatting. misses minor
formatting
issues.
2. Style The report is not Little effort is Evident Effort of Style of writing
capable of exerted trying to get the well engages the
5%
capturing the towards attention of the reader throughout
attention of the capturing the reader the entire report.
reader reader’s
attention
3. Syntax and Little Effort is Some but Report gives Report written in
Grammar done towards insufficient attention to the past tense. No
applying effort is done grammar. sign of any
5%
grammar rules, towards However, it grammatical or
spelling, applying includes some syntax mistakes
punctuation, … grammar rules, minor
spelling, grammatical or
punctuation, … syntax mistakes.
4. Vocabulary Poor vocabulary Some but Major effort Use of discipline
and little use of insufficient towards using specific
5%
discipline effort towards discipline terminology. The
specific using discipline specific report includes a
vocabulary specific terminology. list of
terminology. abbreviations
5. Content The report The report The report The reports
provides limited addresses all addresses the content is
70%
exploration to topics but three topic in full with comprehensive
the topic or more topics one or two and fully
are not fully minor items addresses all
presented missing needed items

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 6. Appropriate Little evidence An inconsistent Use of APA style Appropriate use of
Use of of using any referencing (or an approved APA style (or an
Referencing referencing style style is alternative approved
System adopted. system) for alternative
referencing. system) for
5%
However, some referencing
errors were
spotted.
7. Academic Report appears The report does Report Report
Integrity to be not not provide distinguishes distinguishes
sufficiently clear distinction between clearly between
5%
acknowledging between student’s own student’s own
work of other students’ work work and the work and the
authors. and work of work of others. work of others.
others. This is achieved This is achieved by
by sufficient and sufficient and
appropriate appropriate
citations citations
throughout the throughout the
report. report.

X. Plagiarism

Reference to the students’ handbook.