Additive Manufacturing
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SL creates parts in a vat of liquid resin that is cured in patterns with a UV laser, whose energy is directed with dynamic mirrors. The other half of the model required a special process termed IDLight, offered solely by Stratasys Direct Manufacturing—who provided the entire show model—to incorporate such a large unit devoid of visible seams while resembling skin.
hundreds of considerably involved components. “The design of the human patient simulator is a complex endeavor requiring extensive validation of the components and, in particular, the interaction of the physical parts,” said Giuseppe Mallaci, senior mechanical designer for the CAE Fidelis MFS. “The complexity increases as we introduce moving parts and deformable components in a confined space. Small incremental changes are required to validate such a complex design. In addition, the competitive nature of our industry fuels a growing need for relatively short product development cycles. So, rapid prototypes are essential to the success of any product development initiative.” CAE used rapid prototyping processes from Stratasys Direct
Manufacturing, including fused deposition modeling (FDM), stereolithography (SL), selective laser sintering (SLS) and QuantumCast cast urethanes and rapid machining. “Stratasys responded to our needs for timely prototypes and changes,” said Mallaci. “In all cases, whether it be FDM or SL rapid prints, QuantumCast parts, molded foam parts or molded urethane parts, their team advised on the manufacturing approach best suited to meet our functional needs.” These technologies helped the design team create the interlocking and interacting components that culminated in a fully functional, incredibly true-to-life simulator. The critical components for the simulator were: • Airway—a molded part consisting of complex geometry that also had to be deformable. It needed UV stability and
resistance to abusive user interaction in the form of oral intubation using medical airway adjuncts. • Ribcage—a flexible/deformable body to accurately represent the anatomical features while deforming in a realistic fashion. Subject to much user abuse when CPR is performed. • Articulations—the simulator has extensive articulations to best mimic the human body articulations. To validate the articulations as well as the cable management and component placement, it was imperative to have physical prototypes. • Head assembly—the head assembly consists of many small parts in a confined space. The rapid prototypes were instrumental in validating the design for manufacturability and assembly purposes. The original simulator was introduced to an audience of December 2015
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