King Saud University

College of Engineering
Industrial Engineering
Department

Custom-Made
Artificial Knee

By
Abdullah AlNuiam
Supervised By
Prof. Saied Darwish
 Outline
1) Introduction
2) Objective
3) Artificial Knee joint
4) Biomaterial
5) Mastercam
6) CNC Machine
7) G-codes
8) Conclusions
King Saud University
Industrial Engineering Department
 Introduction:
 Biomedical engineers have long been working on solutions to
design a better replacement joints to improve the lives of the
thousands of patients every year

 The design, manufacture and placement of these artificial joints

require a high degree of skill and a thorough knowledge of
physics, biology and chemistry

:Some examples

•Artificial hips, knees and other joints.

•Ultrasound, magnetic resonance imager (MRI) and other
medical imaging techniques.

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 Types of joints
 Saddle
Ball
Hinge
Gliding
and
joints
joints
socket joints

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Knee Joint

 The knee is the largest joint in the body

 Normal knee function is needed to perform
routine everyday activities
 The most common reason for having a knee
replaced is osteoarthritis.
 Problem definition

This project aims to manufacture a custom made

knee joint locally using MasterCAM to design and
CNC machine to manufacture.

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 :Normal Knee
 The knee is the largest joint in the
body
 Normal knee function is needed
to perform routine everyday
activities
 It consists of:
 Femur: which rotate the
upper end of the shin bone
(tibia)
 Tibia: which is the shin bone
 Patella (knee cap): which
slides in a groove on the
end of the femur.

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?What Is a Knee Replacement
 The most common reason for having a knee
replaced is osteoarthritis.
 Knee replacement, is a surgical procedure in
which the diseased parts of the knee joint are
removed and replaced with new artificial
parts.
 The goals of knee replacement surgery
include increasing mobility, improving the
function of the knee joint, and relieving pain.

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:Surgical Considerations
When choosing an implant, the surgeon will
consider many factors, including the patient's:
 Age
 Weight
 Gender
 Anatomy
 Activity level
 Medical history
 General health

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 How Are Knee Problems Diagnosed
Diagnostic tests depend on the findings of the medical
history and physical exam, such as:
 X-ray
 Computerized axial tomography (CAT) scan
 Bone scan (radionuclide scanning)
 Magnetic resonance imaging (MRI)
 Biopsy
Those tests are needed in designing “custom-made” knee
joint; they show angles and sizes needed to produce a
replacement knee that matches this human's body
structure.

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Injuries

1. Osteoarthritis (OA)
2. Rheumatoid
3. Avascular Necrosis
4. Malalignment of Knee Joint

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 Project Objective:
 The custom-made is the only solution for
tumor patients .
 Hospitals need to convert the x-ray into solid
models that can be manufactured.
 The Objective is to test the visibility of
manufacturing a custom-made artificial knee
joint locally.
 This is to develop a special design to suit
each patient with the minimum possible time
and minimum cost

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Industrial Engineering Department
Knee Replacement

 The complexity of the

knee joint has
presented special
challenges in the design
and insertion of an
artificial joint.
 The knee needs to
allow movement from
zero (straight) to 90
degrees at least.

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 Components of Artificial Knee

 Femur (top)
 Tibia (bottom)
 Polyethylene (in between)

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Types of Knee Replacements

 Depending on the degree of mechanical

stability provided by the design of the artificial
knee, there are three basic categories of
knee replacement:
 Non- constrained
 Semi- Constrained
 Unicondylar

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Progresses in Knee Replacement
 Technology has led to the development of materials
used.
 Major advancements in knee replacement have
greatly improved the outcome of the surgery
 Artificial joint replacement for arthritis of the knee is
one of the most successful surgeries of the last
century
 95% of people are able to begin walking the day
following surgery and pain relief is achieved.

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Advantages of Knee Replacement
 This operation produces very effective and
long lasting relief from joint pain
 It gives a joint which functions normally
 The recovery period from the operation is
very short
 The patient is able to walk from the 2nd or the
3rd day after the operation.
 The patient regains a normal lifestyle and
mobility with significant improvement in
quality of life

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Biomaterial
 Biomaterial are materials used for surgical or dental
instruments and for external prostheses.

 A biomaterial placed within the interior of the body

must be biocompatible.

 It should possess adequate physical and mechanical

properties to serve as replacement of body tissues

 It should be amenable to be formed into different

shapes, have relatively low cost, and be readily
available

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Biomaterial
 The primary materials used in
Total Knee System implant
components include cobalt
chromium molybdenum alloy
(Co-Cr-Mo)

Cross Section of CO-Cr-Mo formal cross sections of tibia base plate

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 Types of Wear

 Abrasive Wear
 Adhesive Wear
 Fatigue Wear
 Third Body Wear

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Role of Industrial Engineer
 Gather information about joint/bones dimensions
using x-rays to come up with suitable knee
replacement sizes
 Develop models for patients come up with an
appropriate combination of cement thickness, offset
distance and femoral head size that will
accommodate the patient's size.
 Implementing CAD/CAM and extracting CNC codes
to manufacture the appropriate knee replacement for
Saudi patients
 Predict the durability of the replacement by modeling the
progress of the wear behavior of replaced components

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 Mastercam
MasterCAM is a commercial Computer Aided
Manufacturing software package includes a CAD
environment, a geometry-to-G-code translator, and
a G-code simulator.

MasterCAM provides full 2D and 3D design

capability for drawing mechanical parts, and
creates output code for programming CNC

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Advantages of MasterCAM
1) Mastercam can build work-holding fixtures,
complex 3D form fixtures, and to build
assemblies.
2) Mastercam allows for fast and easy
development of tool paths.
3) Fast and easy translation between CAD and
CAM files.
4) You can check your work for errors before
the actual machining began, saving the time
and money.

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Manufacturing Process
•The dimensions of the femur of the artificial knee
joints were measured to get the following
dimensions:
Procedure of Manufacturing
1) The blank for the job is prepared by Material
cutting, milling and surface grinding.

2) The workpiece is WIRECUT in the WEDM

machine and so is the holder

3) The workpiece is machined in the upside-

down direction to finish all bottom operations
with material for a screw hole in the center

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Procedure of Manufacturing
4) The workpiece is fixed to the holder with the
screw. The job is held at 45degree to run a
CAM program generated in that direction.

5) The workpiece is than held at another angle

of -45degree to run another CAM program
generated in that direction.

6) The job is polished to achieve the required

finish

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Final Shape

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Machine
 The machine used to
manufacture this
artificial femur knee joint
was a Huron kx-15 five
axis machine
 That device is very
appreciated for the
machining of very
technical and complex
work pieces

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 CNC Controller

CNC stands for

"Computer
Numeric Control".
It's referring to
machinery that is
under automated
control, as
opposed to
manually by an
operator.```

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Industrial Engineering Department
 G-Codes
What is G-code?
When the designed product is produced using CNC
machine tools, the machine tool controller needs
explicit instructions describing the type and order of
individual steps required to perform a given task.
These instructions are provided to the controller in
the form of alphanumeric codes (G-code) and are
usually called a part program.

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Sample of G-Codes
%
(PROGRAM NAME - Knee joint)
N100G21
N102G0G17G40G49G80G90
(UNDEFINED TOOL - 1 DIA. OFF. - 41 LEN. - 1 DIA. - 6.)
N104T1M6
N106G0G90G54X-101.307Y2.758A0.S50M5
N108G43H1Z60.
N110Z-.354
N112G1Z-5.354F0.
N114X-101.21Z-5.137
N116X-101.043Z-4.837
N118X-100.959Z-4.66
N120X-100.71Z-4.24
N122X-100.691Z-4.203
N124X-100.622Z-4.095
N126X-100.41Z-3.839
N128X-100.248Z-3.676
N130X-100.126Z-3.542
N132X-99.986Z-3.416
N134X-99.824Z-3.314

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Sample of G-Codes
N1178X-37.64Z-7.54
N1180X-37.614Z-7.595
N1182X-37.451Z-8.398
N1184X-37.356Z-8.975
N1186Z-3.975
N1188G0Z-2.858
N1190X-39.326Y48.883
N1192G1Z-3.886
N1194Z-8.886
N1196X-39.808Z-8.589
N1198X-57.292Z-8.59
N1200X-57.547Z-8.841
N1202Z-3.841
N1204G0Z-3.84
N1206X-81.326
N1208G1Z-3.886
N1210Z-8.886
N1212X-81.808Z-8.589
N1214X-99.292Z-8.59
N1216X-99.547Z-8.841
N1218Z-3.841
N1220M5
N1222G91G0G28Z0.
N1224G28X0.Y0.A0.
N1226M30
%

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Tool path for the model
Video of Process

1st set up

2nd set up

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 Conclusions

 The present work shows that artificial knee joint could

be manufactured locally.

 The MasterCAM proved sufficient, not only to

represent the femur part of the joint, but also to
generate tool path and G-codes necessary to
manufacture the femur part of the joint.

 This success will hopefully have a reflection on the

manufacture of custom-made artificial knee. This is
expected to help reduce the suffering of our patients.

King Saud University

Industrial Engineering Department
 … Thank You

Special thanks to my adviser

Prof. Darwish

King Saud University

Industrial Engineering Department