DESIGN AND FABRICATION OF SPINAL CORD USING

FDM PROCESS

A MINOR PROJECT REPORT

Submitted by

KONDURU NETHAJI (19UEME0106)

RAJASEKHARA REDDY (19UEME0231)

CHEDEPUDI SASHANK REDDY (19UEMT0002)

in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING
Guided by

Dr. A. S. PRAVEEN Ph.D.

Associate Professor in Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING SCHOOL OF

MECHANICAL AND CONSTRUCTION

NOVEMBER 2022
 BONAFIDE CERTIFICATE

Certified that this rteport titled “DESIGN AND FABRICATION OF SPINAL CORD

USING FDM PROCESS” is the bonafide work of KONDURU NETHAJI

(19UEME0106), RAJASEKHARA REDDY (19UEME0231) and CHEDEPUDI

SASHANK REDDY (19UEMT0002) who carried out the work under my supervision.

Certified further that to the best of my knowledge the work reported herein does not

form part of any other thesis or dissertation on the basis of which a degree or award was

conferred on an earlier occasion on this or any other candidate.

Signature of the Supervisor Signature of the HOD

Dr. A. S. PRAVEEEN
Associate Professor
Department of Mechanical Engineering
Vel Tech Rangarajan Dr. Sagunthala R&D
Institute of Science and Technology
Chennai – 600 062
Dr. N. LENIN
Professor and Head
Department of Mechanical Engineering
Vel Tech Rangarajan Dr. Sagunthala R&D
Institute of Science and Technology
Chennai – 600 062
 CERTIFICATE OF EVALUATION

PROGRAM : Bachelor of Technology

BRANCH : Mechanical Engineering
SEMESTER : VII

Name of the Student KONDURU NETHAJI (19UEME0106)

RAJASEKHARA REDDY (19UEME0231)
CHEDEPUDI SASHANK REDDY (19UEMT0002)

Title of the Project “DESIGN AND FABRICATION OF SPINAL CORD

USING FDM PROCESS”

Name of the Guide Dr. PRAVEEN .A. S.

Associate Professor, Mechanical Engineering,
Vel Tech Rangarajan Dr. Sagunthala R&D Institute
of Science and Technology

The report of the project work submitted by the above students in partial fulfilment for
the award of Bachelor of Technology in Mechanical Engineering of Vel Tech
Rangarajan Dr. Sagunthala R&D Institute of Science and Technology for the Viva -
Voce Examination held on ____-____-______ has been evaluated and confirmed to the
report of work done by the above students.

INTERNAL EXAMINER EXTERNAL EXAINER

Name: Name:
Designation: Designation:
Affiliation:

iii
 ABSTRACT

Three-dimensional (3D) printing has revolutionized medical training and patient care.

Clinically it is used for patient-specific anatomical modeling with respect to surgical

procedures. 3D printing is heavily implemented for simulation to provide a useful tool

for anatomical knowledge and surgical techniques. Fused deposition modeling (FDM)

is a commonly utilized method of 3D printing anatomical models due to its cost-

effectiveness. A potential disadvantage of FDM 3D printing complex anatomical shapes

is the limitations of the modeling system in providing accurate representations of

multifaceted ultrastructure’s, such as the facets of the lumbar spine. In order to utilize

FDM 3D printing methods in an efficient manner, the pre-printing G-code assembly

must be oriented according to the anatomical nature of the print. Polyether ether ketone

(PEEK) is an efficient semi-crystalline thermoplastic alternative to implantable metal

materials as it has excellent biocompatibility and combines good strength and stiffness.

The elastic modulus of PEEK is similar to cortical bone, which reduced stress shielding

after implantation. It is also radiolucent which permits radiographic assessment. The

combination of these properties has made PEEK great potential for orthopedic

application. Medical grade PEEK-OPTIMA has been developed by Invidia to meet food

and Drug Administration (FDA) requirements and has been used in multiple clinical

applications such as spinal cage fusion, total joint replacement, and craniomaxillofacial

reconstruction.

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 ACKNOWLEDGEMENT

We would like to express our gratitude and heartfelt appreciation to our esteemed
Founder Chancellor and President Col. Prof. Dr. R. RANGARAJAN B.E. (ELEC),
B.E. (MECH), M.S (AUTO), D.Sc. and Founders President Dr. SAGUNTHALA
RANGARAJAN M.B.B.S., for providing us with an ambient learning experience at
our institution.

We take great pride in expressing our heartfelt appreciation to our beloved Vice
Chancellor Prof. Dr. S. SALIVAHANAN., Ph.D., Registrar Dr. E. KANNAN.,
Ph.D., and Dean Academics Dr. A.T. RAVICHANDRAN., Ph.D., for encouraging us
to complete my project and serving as inspiration for us to perform well.

We furthermore thank Dr. S. IRUDAYARAJ, Ph.D., Dean of the School of

Mechanical and Construction, for his constant encouragement and valuable academic
support in all aspects.

It gives us great pleasure to recognize the assistance and contributions of our Department
Head, Dr. N. LENIN., Ph.D., for his encouragement and unwavering support throughout
the duration of this project.

We would like to express our gratitude to our Project Guide, Dr. A. S. PRAVEEN,
Ph.D., for his unwavering support throughout the duration of this project and for
providing methodologies for carrying out the work required to complete my project
work.

We would like to thank our Project Reviewer, Dr. S. JAYAVELU., for his suggestions
and comments throughout the course of this project.

Most importantly, we would like to thank our Teaching and Non-Teaching Staff for
their assistance throughout the Program's study. We also want to express our heartfelt
gratitude to our parents and friends for their unwavering support.

(KONDURU NETHAJI)
(BYREDDY RAJASEKHARA REDDY)
(CHEDEPUDI SASHANK REDDY)

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 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

NO.
ABSTRACT Iv
LIST OF TABLES Viii
LIST OF FIGURES Ix
LIST OF ABBREVIATIONS X

1 INTRODUCTION 1
1.1 FUSED DEPOSITION MODELLING 1
1.1.1Drive Block 2
1.1.2Heating chamber 2
1.1.3Tips 3
1.2 Spinal Cord 3

1.3 Polyether Ether Ketone 4

1.4 MATERIALS 5

1.4.1 Polylactic Acid 5

1.4.2 Mimics Software 6

1.4.3 Slicer Software 6

1.4.4 Creatdot 7

1.5 OBJECTIVE 8
1.6 METHODOLOGY 8
1.7 OUTLINE OF REPORT 9

2 LITERATURE REVIEW 10

2.1 LITERATURE 10
3 EXPERIMENTAL PROCEDURE 14

3.1 PROCEDURE 14
3.1.1 CT Scan 14
3.1.2 using slicer software 15

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 3.1.3 mimics software 16

3.1.4 3d printing 17
3.1.5 post processing 18

3.1.6 curing 19
4 TESTING AND RESULTS 20
4.1 OBSERVATION 20
4.2 PRINTING PROCEDURE 21
4.3 DESIGN OF MODEL 22
4.4 RESULT 23
4.5 COST ESTIMATION 24
5 CONCLUSION AND SCOPE FOR FUTURE 25
WORK
5.1 CONCLUSION 25
5.2 SCOPE FOR FUTURE WORKS 25
REFRENCES 26

vii
 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

4.1 Cost Estimation 24

viii
 LIST OF FIGURES

FIGURE. NO. TITLE PAGE NO

1.1 Fuse Deposition Modelling 1

1.2 Parts Of FDM 2

1.3 Spinal cord 4

1.4 Structure of PEEK 5

1.5 Polylactic acid 6

1.6 3D printer 7
1.7 Project methodology 8

3.1 A person being scanned in the computer 14

tomography

3.2 Views of the image in slicer 15

3.3 mimics Software 16

3.4 3D Printing Of Spinal cord 17

3.5 Post Processing 18

3.6 Curing 19
4.1 Final Product 20

4.2 Design of model 22

ix
 LIST OF ABBREVIATIONS

3D Three Dimensions
CT Scan Computer Tomography Scan
DICOM Digital Imaging And Communications In Medicine

FDM Fuse Deposition Modelling

ICI Imperial Chemical Industries

PEEK Polyether Ether Ketone

PLA Polylactic Acid

STL Standard Triangle Language

x
 CHAPTER 1
INTRODUCTION
A steady filament of a thermoplastic polymer is utilized to 3D print layers of
materials in the FDM process. The fiber is heated by sideways of the nozzle to show up
at a semiliquid state and a short time later removed on the stage or on the head of late
printed layers. The thermoplastic of the polymer filament is a major property in this
process, which permits the filament to consolidate in the course of printing and, a while
later, to fix at room temperature in the rouse of printing. The deposit fatness, width and
course of filament, and air opening are essential in getting ready limits that impact the
mechanical properties of printed components. Amid layer, meandering was viewed as
the central driver of mechanical deficiency. Quick and easy operation techniques are the
principal points of interest in FDM. In contrast, feeble-mechanical behaviors, layer by
layer arrival, powerless surface quality, and a foreordained number of thermoplastic
materials are the guideline weaknesses of FDM. The headway of fiber-strengthened
composites making use of FDM has been fortified. the mechanical properties of 3D
components the elastic modulus of PEEK is similar to cortical bone, which reduced
stress shielding after implantation. It is also radiolucent which permits radiographic
assessment.
1.1 FUSED DEPOSITION MODELLING (FDM)

Figure. 1.1: Fused deposition modelling

1
 The FDM is based on surface chemistry (interface of two surface), thermal
energy, and layer manufacturing technology. Figure. 1.1 explain the design of FDM and
the way of process The material in filament (spool) form is melted in a specially
designed head, which extrudes on the model. As it is extruded, it is cooled and thus
solidifies to form the model. The model is built layer by layer, like the other RP
systems. Figure. 1.2 shows the three main components 1. Drive blocks 2. Heating
chamber 3.Tip

Figure. 1.2: parts of FDM

1.1.1: DRIVE BLOCKS

The drive blocks are the raw-material feeding mechanisms, and are mounted on
the back of the head. The drive blocks are computer controlled and are capable of
precision loading and unloading of the filament. It consist of two parallel wheels
attached to a small electric motor by gears. The wheels have a plastic or rubber
materials, and are rotate opposite to one another The filament is placed between them, it
continue to push or pull the material, depending on the direction of rotation. When
loading, the filament is pushed horizontally into the head through a hole which is the
entry to the heating chamber.

1.1.2: HEATING CHAMBER

The heating chamber is a 90-degree curved elbow enclosed in a heating element,

which serves two primary functions. • One is to change the direction of the filament
flow so that the material is extruded vertically downward. • Secondly, and most

2
important, is to serve as a melting area for the material. The heating element is
electronically controlled, and has feedback devices to allow for a constant temperature
throughout. The heating elements are held at a temperature just above the melting point
of the material, so that the filament passing from the exit of the chamber is in a semi-
molten state. At the end of the heating chamber, the extrusion orifice or tip is attached

1.1.3: TIPS (NOZZLE)

The tips are attached into the heating chamber exit, and are used to reduce the
extruded filament diameter to allow for better detailed modeling. The tips can be
removed and replaced with different size openings. The extruding surface of the tip is
flat, serving a smooth upper finish of the extruded material. The tip is the point at which
the material is deposited to build the model.
1.2 SPINAL CORD
The spinal cord is a long, thin, tubular structure made up of nervous tissue, which
extends from the medulla oblongata in the brainstem to the lumbar region of the
vertebral column (backbone). The backbone encloses the central canal of the spinal
cord, which contains cerebrospinal fluid. The brain and spinal cord together make up
the central nervous system (CNS). In humans, the spinal cord begins at the occipital
bone, passing through the foramen magnum and then enters the spinal canal at the
beginning of the cervical vertebrae. The spinal cord extends down to between the first
and second lumbar vertebrae, where it ends. The enclosing bony vertebral column
protects the relatively shorter spinal cord. It is around 45 cm (18 in) long in adult men
and around 43 cm (17 in) long in adult women. The diameter of the spinal cord ranges
from 13 mm (1⁄2 in) in the cervical and lumbar regions to 6.4 mm (1⁄4 in) in the thoracic
area.
The Figure. 1.3 shows the spinal cord functions primarily in the transmission of
nerve signals from the motor cortex to the body, and from the afferent fibers of the
sensory neurons to the sensory cortex. It is also a center for coordinating many reflexes
and contains reflex arcs that can independently control reflexes. It is also the location of
groups of spinal interneurons that make up the neural circuits known as central pattern
generators. These circuits are responsible for controlling motor instructions for
rhythmic movements such as walking.

3
 Figure. 1.3: Spinal Cord

1.3. POLYETHER ETHER KETONE (PEEK)

Polyether ether ketone (PEEK) is a colorless organic thermoplastic polymer in
the polyether ether ketone (PEEK) family, used in engineering applications. The
polymer was first developed in November 1978, later being introduced to the market by
Valtrex PLC, then Imperial Chemical Industries (ICI) in the early 1980s. PEEK is a
semi crystalline thermoplastic with excellent mechanical and chemical resistance
properties that are retained to high temperatures. The processing conditions used to
moul PEEK can influence the crystallinity and hence the mechanical properties. Its
Young's modulus is 3.6 GPa and its tensile strength is 90 to 100 MPa. PEEK has a glass
transition temperature of around 143 °C (289 °F) and melts around 343 °C (662 °F).
Some grades have a useful operating temperature of up to 250 °C (482 °F). The thermal
conductivity increases nearly linearly with temperature between room temperature and
solidus temperature. It is highly resistant to thermal degradation, as well as to attack by
both organic and aqueous environments. It is attacked by halogens and strong Bronzed
and Lewis acids, as well as some halogenated compounds and aliphatic hydrocarbons at
high temperatures. It is soluble in concentrated sulfuric acid at room temperature,
although dissolution can take a very long time unless the polymer is in a form with a
high surface-area-to-volume ratio, such as a fine powder or thin film. It has high

4
resistance to biodegradation. Figure. 1.4 explain about the structure of the PEEK

Figure. 1.4: Structure of PEEK

1.4 MATERIALS

Polyether ether ketone (PEEK), PLA, Mimes software, slicer software, Dicom file,
Creatbot

1.4.1 Polylactic acid (PLA)

Polylactic acid, also known as poly(lactic acid) or polylactide (PLA), is

a thermoplastic polyester with backbone formula (C3H4O2)n or [–C(CH3)HC(=O)O–]n,
formally obtained by condensation of lactic acid C(CH3)(OH)HCOOH with loss of
water (hence its name). It can also be prepared by ring-opening polymerization
of lactide [–C(CH3)HC(=O)O–]2, the cyclic dimer of the basic repeating unit.

PLA has become a popular material due to it being economically produced

from renewable resources. In 2010, PLA had the second highest consumption volume
of any bio plastic of the world,[3] although it is still not a commodity polymer. Its
widespread application has been hindered by numerous physical and processing
shortcomings. PLA is the most widely used plastic filament material in 3D printing. Its
low melting point, high strength, low thermal expansion, good layer adhesion, and high
heat resistance when annealed make it an ideal material for this purpose. Without
annealing, however, PLA has the lowest heat resistance of the common 3D printing
plastics.
Although the name "polylactic acid" is widely used, it does not comply
with IUPAC standard nomenclature, which is "poly(lactic acid)". The name "polylactic
acid" is potentially ambiguous or confusing, because PLA is not a polyacid
(polyelectrolyte), but rather a polyester. Figure. 1.5 explain about the structure of PLA

5
 Figure. 1.5: Polylactic acid

1.4.2 Mimics Software

Materialise Mimics is an image processing software for 3D design and
modeling, developed by Materialise NV, a Belgian company specialized in additive
manufacturing software and technology for medical, dental and additive manufacturing
industries. Materialise Mimics is used to create 3D surface models from stacks of 2D
image data. These 3D models can then be used for a variety of engineering applications.
Mimics is an acronym for Materialise Interactive Medical Image Control System. It
is developed in an ISO environment with CE and FDA 510k premarket clearance.
Materialise Mimics is commercially available as part of the Materialise Mimics
Innovation Suite, which also contains Materialise 3-matic, a design and meshing
software for anatomical data. The current version is 24.0(released in 2021), it
supports Windows 10, Windows 7, Vista and XP in x64.

1.4.3 Slicer software

The slicer, also called slicing software, is computer software used in the
majority of 3D printing processes for the conversion of a 3D object model to specific
instructions for the printer. In particular, the conversion from a model in STL format to
printer commands in g-code format in fused filament fabrication and other similar
processes. The slicer first divides the object as a stack of flat layers, followed by
describing these layers as linear movements of the 3D printer extruder, fixation laser or
equivalent. All these movements, together with some specific printer commands like the
ones to control the extruder temperature or bed temperature, are finally written in the g-

6
code file, that can afterwards be transferred to the printer.

1.4.4 Creatbot

CreatBot has specialized in manufacturing high temperature 3D printers for

more than five years, and has a wealth of 3D printing and material identification
experience for various high performance materials. The manufacturer’s machines offer
exactly what you’d expect from a high temperature 3D printer, but at a fraction of the
cost compared to other 3D printers on the market. Figure. 1.6 shows the 3D printer we
used

Figure. 1.6: 3D Printer

PEEK-300 Specifications

Build volume 300 x 300 x 400mm

Min. layer thickness 0.04mm

Max. printing speed 150 mm/s

Max. nozzle temperature 500°C

7
Max. bed temperature 200°C

Max. build chamber temperature 120°C

Annealing temperature 0-400°C

XY positioning precision 11μm

Z positioning precision 2.5μm

Dimensions 650 x 600 x 750mm

Weight 130kg

1.5 OBJECTIVE
This project aims to study:
➢ To design spinal cord through CT scan using slicer software
➢ To fabricate spinal cord by using the FDM method
1.6 METHODOLOGY

In this, following methodology as shown in Figure. 1.7 was adopted.

Get the patient detail and send him to CT scan

Getting a DICOM (Digital Imaging and Communications in Medicine)

file

Extracting a 3D model from the Dicom file

Finding the damaged part of the spinal cord

Extract the required bone to be replaced

8
 Converting the 3D model into STL format

Manufacturing the product

Figure. 1.7: Project Methodology

1.7 OUTLINE OF THE REPORT

This report comprises five chapters, they are briefly discussed as follows:
Chapter 1: General introduction, objective and methodology of work is presented.
Chapter 2: A brief review of literature is shown.
Chapter 3: Deals with the experimental
Chapter 4: Results of experiments are discussed. Chapter 5: Present the conclusion
derived from work.

9
 CHAPTER 2

LITERATUE REVIEW

2.1 LITERATURE

Damon et al. (2020) done a research on Orientation Planning in the Fused

Deposition Modeling 3D Printing of Anatomical Spine Models This article describes
the approach that our institution's 3D printing laboratory has used to manipulate
models’ printing angles in regard to the print bed and nozzle, according to anatomical
properties, thus creating quality and cost-effective anatomical spine models for
education and procedural simulation.

Vaezi and Yang (2015) carried out research on Extrusion-based additive

manufacturing of PEEK for biomedical applications. We learn about the PEEK is a
biocompatible material with favorable properties that allow for its use in restorative
dentistry for various treatment options and applications.

Bogna et al (2013) did research on Tensile bond strength of veneering resins to

PEEK: Impact of different adhesives This article describes the approach (TBS) between
veneering resins and polyetheretherketone (PEEK) after pre-treatment with adhesive
systems. Five-hundred-seventy-six PEEK disks were fabricated, air-abraded and
divided into six pre-treatment groups (n=96/group): Z-Prime Plus, Ambarino P60,
Monobond Plus, Visio.link, Signum PEEK Bond, and control group without pre-
treatment.

HongyunMa et al (2021) done research on PEEK (Polyether-ether-ketone) and

its composite materials in orthopedic implantation Twelve consecutive patients (75%
males; mean age = 43, range 16-67) underwent PEEK cranioplasty between January
2011 and December 2012 after a mean time interval of 10 months (range 3-40)
following initial craniectomy. It shows positive reviews.

10
 Bandyopadhyay and S. Bose(2015) Additive Manufacturing, CRC Press,
Florida, Fla. USA,. Done research on polyetheretherketone in the fabrication of a
maxillary obturator prosthesis A systematic search was conducted using Cochrane
library, MEDLINE(PubMed), Ovid MEDLINE, Web of Science and EMBASE
databases. Publications were identified in accordance with specific inclusion and
exclusion criteria.

Gibson et al (2010) Done research on Additive Manufacturing Technologies:

Rapid Prototyping to Direct Digital Manufacturing, Springer Traditional cranioplasty
methods focus on pre-operative or intraoperative hand molding. Recently, CT-guided
polyetherether ketone (PEEK) plate reconstruction enables precise, time-saving
reconstruction

P. A. Lioufas et al (2014) Done research on "3D printed model of cleft palate

pathology for surgical education," Plastic and Reconstructive Surgery-Global Open
This case series aims to show a single institution experience with use of PEEK
cranioplasty as an effective, safe, precise, reusable, and time-saving cranioplasty
technique in large, complex cranial defects.

E. Vezzetti et al (2015) Done research on "Diagnosing cleft lip pathology in 3D

ultrasound: A landmarking-based approach The best material choice for cranioplasty
following craniectomy remains a subject to discussion. Complication rates after
cranioplasty tend to be high. Computer-assisted 3-dimensional modelling of
polyetheretherketone (PEEK) was recently introduced for cranial reconstruction.

M. Javaid and A. Haleem, (2017) Done research on "Additive manufacturing

applications in medical cases: a review," lthough many devices, the so-called 3D
printers, operates automatically specialist expertise is necessary to ensure efficient and
accurate results. After the AM phase, some manufactured objects require
11
postprocessing, for example, coating, polishing, or sterilization

S. Mazzoni, et al (2017) Done research on "Computer-aided design and

computer-aided manufacturing cutting guides and customized titanium plates are useful
in upper maxilla waferless repositioning." Journal of Oral and Maxillofacial Surgery,

R. Schwarzkopf et al (2011) Done research on "Surgical and Functional

Outcomes in Patients Undergoing Total Knee Replacement with Patient- Specific
Implants Compared With "Off-the-Shelf Implants." Orthopaedic Journal of Sports
Medicine

Bandyopadhyay and S. Bose(2015) Additive Manufacturing, CRC Press,

Florida, Fla. USA,. Done research on polyetheretherketone in the fabrication of a
maxillary obturator prosthesis A systematic search was conducted using Cochrane
library, MEDLINE(PubMed), Ovid MEDLINE, Web of Science and EMBASE
databases. Publications were identified in accordance with specific inclusion and
exclusion criteria.

Toth J et al (2010) Done research on Polyetheretherketone as a biomaterial for

spinal applications. Biomaterials from this article we learn about Threaded lumbar
interbody spinal fusion devices (TIBFD) made from titanium have been
reported to be 90% effective for single-level lumbar interbody fusion, although
radiographicdetermination of fusion has been intensely debated in the literature.

Najeeb S and Zafar M (2016) Done research on Applications of polyethere-

therketone (PEEK) in oral implantology and prosthodontics. Models from this article
we learn about How the PEEK is going under the process of oral implantology and
prosthodontics will improve the final quality of the 3d printing product by using FDM
Yang et al (2015) carried out research on Extrusion-based additive manufacturing of
12
PEEK for biomedical applications. We learn about the PEEK is a biocompatible
material with favorable properties that allow for its use in restorative dentistry for
various treatment options and applications.

Bandyopadhyay and S. Bose(2015) Additive Manufacturing, CRC Press,

Florida, Fla. USA,. Done research on polyetheretherketone in the fabrication of a
maxillary obturator prosthesis A systematic search was conducted using Cochrane
library, MEDLINE(PubMed), Ovid MEDLINE, Web of Science and EMBASE
databases. Publications were identified in accordance with specific inclusion and
exclusion criteria.

13
 CHAPTER 3
EXPERIMENTAL PROCEDURE

3.1 PROCEDURE
In this Experiment we are going to prepare a spinal cord using Fused Deposition
Moulding (FDM)
3.1.1 CT SCAN
First finding the problem of patient according to the seriousness doctor will
desert he need general surgery or replacement of implant. And after we will first take a
CT scan of the patient CT scan will provide many 2D images of the body the combining
of all 2D images is called as a Dicom file. We will take these CT scan and the files with
the consent of the patient with fulfilling all formalities without any hassle of further
issues. This CT scan will be further preceded for the project initiation. Figure. 3.1 show
the CT scan taking place

Figure. 3.1: A person being scanned in the computer Tomography Scan

14
3.1.2 USING SLICER SOFTWARE.
With the help of dicom file we will generate a 3D image of skeleton by using
slicer software and doctor will identify the particular portion and guide to the
differentiate the required part of bone then we extract the required part of the spinal
cord and edit the required position of the spine. We used Slicer for initial expansion of
the required part of the CT scan, we used the 3-D view in the application. Slicer, is a
user free App which helped us out to explore freely on what basis we needed to develop
the project. Figure. 3.2 shows how we can view the DICOM file in the Slicer software

Figure. 3.2: Views of the image in slicer

15
3.1.3 MIMICS SOFTWARE
We uploads our diecom file into the mimics software and addied the required
position of the spinal. Mimics software was used for the advanced level editing
compared to the other one.The project final picture mostly relies on this software as we
used this for the converstion of the dicom file to STL file . Figure. 3.3showes the view
of mimics software

Figure. 3.3: mimics Software

16
3.1.4 3D PRINTING
Copy STL file into pen drive and upload the STL file into 3d printer And
Figure. 3.4 showes the 3d printer with printing layer by layer. We used a 3-D printer
called as CreatBot , specialized in high temperature manufacturing, with this we made a
prototype using the peak material. It took time for the prototype completion (mins), the
prototype generated was small in size but not the same as the original one (would be a
replica of the original copy).

Figure. 3.4: 3D Printing Of Spinal cord

17
3.1.5 POST PROCESSING
The Post processing Is the process where the prototype is furnished from extra
unnecessary things which is being printed. Even if any manufacturing damages caused
or occurred in the further process will be rectified and processed and further changes
will be made. Post-processing is an often-overlooked part of the 3D printing process. As
the additive manufacturing market moves from prototyping to end part production
geared to consumer markets, the look and feel of 3D printed products is becoming
increasingly more important. Figure. 3.5 shows the supporting structure what we need
to remove in this process

Supporting structure

Figure. 3.4: Post Processing

18
3.1.6 CURING
It is the process of applying UV light and heat to improve the stability and
strength of 3-D printed images. Also, exposure of light would trigger the formation of
the additional chemical bonds within a 3-D printed part making it more-stronger, and
stiff in nature. Figure. 3.6 explain the exact view where the extract layers of the printing

Figure. 3.4: Curing

19
 CHAPTER 4
TESTING AND RESULTS

4.1 OBSERVATION
Finally, Figure 4.1 shows the spinal cord where we using the FDM process and
made it with the Polyetheretherketone (PEEK) material it took a material of around 15
grams to print the bone and it took the time 1.5 hour for printing. It took 30 min to
remove all the support beams of the finished product.

Figure. 4.1: Final Product

20
4.2 PRINTING PROCEDURE

Fused deposition modeling (FDM) uses a filament that is fed from a large
coil through a moving printer extruder head. This heated printer head liquefies
the thermoplastic and deposits it on the printer bed, which moves in the Z plane in order
to provide height to the desired print. The print head is moved under a defined coding
sequence to form the printed shape in the X and Y planes. The speed of the extruder
may also be controlled to form an interrupted plane without stringing or dribbling
between sections. The head moves in two dimensions (X-Y) to deposit one horizontal
plane, or layer, at a time, and the print bed is then moved vertically (Z) by a small
amount to begin a new vertical layer. Layers are stacked to create a defined shape and
or model. The FDM printer is capable of creating high-end prototypes or
medical models, but requires the operator to perform calibration for component speeds
and temperatures to get the best results. This has led to the argument that FDM printers
can provide more nuisance than benefit due to the requirement for more initial
programing work

However, FDM printing is cost-effective and provides the ability to manipulate

STL files in a virtual manner to exploit the natural properties of the filament used and
the complex shape of the print. The variety and continual innovation of new
thermoplastics makes for an endless possibility of material selection. There are also cost
benefits associated with FDM printing. Low cost materials can be used to create and
refine prototypes of models before the final prints. One of the most advantageous
properties of FDM printing is the ability to manipulate infill or internal density and
structures, thus saving material and allowing for variability in models.

Electro spinning can produce oriented matrices and prepare

ideal bridge prostheses, which can affect the axon orientation and growth of the array.
In addition, by improving the electrospinning equipment and technology, a variety of
fiber forms were stimulated, including twisted, core-shell, hollow, porous, and side-by-
side multilayer surface structures. To simulate the natural environment of spinal cord
tissue, prepared 3D layered fibrin hydrogels with directional structure and hardness
using electrospinning and molecular self-assembly. The electro spun aligned fibrin

21
hydrogel (AFG) fibers were stacked into 2 mm wide bundles and then cut into 4 mm
long lengths to fit the SCI injury gap. It is worth noting that the gross image of
the assembled AFG scaffold was like that of the spinal cord. The elasticity of AFG and
random fibrin hydrogel (RFG) was identical to that of the ECM of nerve tissue, which
was 1.57 ± 0.11 kPa and 0.36 ± 0.02 kPa, respectively

4.2 DESIGN OF MODEL

The Figure. 4.2 shows the exact view of the spinal cord

Figure. 4.2: Design of Model

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 4.3 RESULT

Spinal cord injury it is one of the most damaging human pathologies, severely
impacting the quality of life and the overall society. Since the pathology of SCI is
robust and evolving in nature with the progressive interplay between different
molecular and biochemical cascades, therapies designed to control only one aspect of
these cascades cannot modulate and control the parallel axes that indirectly or
directly influence the selected axis. The first challenge is to prevent the progression
of cascades of subsidiary injury. The second challenge is to regenerate the injured
spinal cord and to restore neuronal connectivity. Therefore, we recommend tailoring the
incorporation of biological and engineering approaches derived from the identified
interplay between their respective mechanisms throughout recovery from SCI. In this
regard, polymer-based therapy can play an essential role as it can hence neuroprotection
and promote axon regeneration. Especially, polymer-based therapies can play a dual
role in neuroprotective, as well as neurogenerative therapeutics and acting as a scaffold
for tissue engineering and cell-based treatments to
enhance rejuvenation. Additionally, the polymer, in combination with
proliferation factors and the neuroprotective agent, could prospectively
promote rejuvenation and functional recovery after SCI.

23
Table 4.1 COST ESTIMATION

S.no Scientific Requirements Cost in INR

1 Peek material 2500

2 PLA 500

3 Operating Cost 500

4 CT Scan 6000

5 Doctor fee 500

TOTAL 10000

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 CHAPTER 5
CONCLUSION AND SCOPE FOR FUTURE WORK

5.1 CONCLUSION
Spinal cord injury is one of the most damaging human pathologies, severely
impacting the quality of life and the overall society. Since the pathology of SCI is
robust and evolving in nature with the progressive interplay between different
molecular and biochemical cascades, therapies designed to control only one aspect of
these cascades cannot modulate and control the parallel axes that indirectly or directly
influence the selected axis. The first challenge is to prevent the progression of cascades
of subsidiary injury. The second challenge is to regenerate the injured spinal cord and to
restore neuronal connectivity. Therefore, we recommend tailoring the incorporation of
biological and engineering approaches derived from the identified interplay between
their respective mechanisms throughout recovery from SCI. In this regard, polymer-
based therapy can play an essential role as it can hence neuroprotection and promote
axon regeneration. Especially, polymer-based therapies can play a dual role in
neuroprotective, as well as neurogenerative therapeutics and acting as a scaffold for
tissue engineering and cell-based treatments to enhance rejuvenation. Additionally, the
polymer, in combination with proliferation factors and the neuroprotective agent, could
prospectively promote rejuvenation and functional recovery after SCI.

5.2 SCOPE FOR FUTURE WORKS

• The human bones are not identical so we can’t make standard size. we should
make individually, so additive manufacturing is best alternative.
• By comparing the traditional method additive manufacturing product will come
with less weight strength
• By comparing the traditional method additive manufacturing product will come
with less weight and equal strength
• lifespan of any traditional prosthetic is around 5 years. Considering the growth
rate of children, they need prosthetics much more frequently.

25
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