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The manufacturing process of metallic implants is critical due to their integration within the patient’s body. The casting route for producing such implants is consistently criticized, as achieving defect-free cast parts demands significant resources and technical expertise. Although rapid prototyping (RP) in metal casting is a well-established technology, it requires further refinement for orthopedic implant production. This paper explores the feasibility of sand casting implants, specifically considering the use of fused deposition modeling (FDM) techniques for RP pattern generation and the customization of implants. Casting simulation was utilized to enhance the accuracy of sand casting. Confirmatory experiments demonstrate that medical-grade implants can be fabricated with minimal defects through the casting process.

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Fabrication of Customized Orthopedic Metallic Implants by Sand Casting

  • 会议论文

  • 发表日期：

    2025年

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  • Subodh Daronde,
  • Abhay Kuthe,
  • Ashutosh Bagde,
  • Bhupesh Sarode

摘要

The manufacturing process of metallic implants is critical due to their integration within the patient’s body. The casting route for producing such implants is consistently criticized, as achieving defect-free cast parts demands significant resources and technical expertise. Although rapid prototyping (RP) in metal casting is a well-established technology, it requires further refinement for orthopedic implant production. This paper explores the feasibility of sand casting implants, specifically considering the use of fused deposition modeling (FDM) techniques for RP pattern generation and the customization of implants. Casting simulation was utilized to enhance the accuracy of sand casting. Confirmatory experiments demonstrate that medical-grade implants can be fabricated with minimal defects through the casting process.