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The revision of ceramic inlays of acetabular cups is a challenging surgical procedure. The mechanical impact during the inlay extraction process can damage the ceramic or metal cup rim. To avoid these risks, a concept for a new revision procedure was developed. It is based on an actuator system, which allows a non-destructive release of the ceramic inlay. To integrate the actuator system, different design concepts of acetabular cup components were investigated, and an actuator based on shape-memory alloy (SMA) wires was developed. The process chain for the actuator, starting from nickel-titanium wires manufactured into the actuator geometry by laser welding and thermo-mechanical treatment for the shape setting process up to the functionality evaluation of the actuator system, was implemented on a laboratory scale. The new revision procedure is based on a phase transformation of the SMA wire actuator, which was obtained through two methods—applying an electrical current by an instrument and rinsing the wire with heated water. The phase transformation of the actuator resulted in a contraction between 3.2% and 4.3% compared to its length after pre-stretching and was able to release the ceramic inlay from the cup. Therefore, the developed actuator design and process chain is a proof of concept towards a new revision procedure for modular acetabular cups.

Compared to sensible heat storage, latent heat storage provides higher energy density due to the enthalpy difference of the storage medium undergoing a phase change. However, the heat storage capability of phase change materials is opposed by low thermal conductivity. To enable sufficient heat transfer within a latent heat storage unit, phase change materials can be used in combination with a metallic matrix. One approach is the infiltration of phase change materials into additively manufactured metallic lattice structures. In this work, the fabrication of aluminum lattice structures through laser powder bed fusion is described. During fabrication, the cell size and the strut diameter were varied to obtain specimens of different geometries. To obtain the thermal conductivity of the fabricated lattices, measurements were conducted based on the transient plane source method. Additionally, finite element simulations were carried out to evaluate the effect of fabrication and measurement uncertainties. The thermal conductivity of the fabricated lattices was found to be between 3 W/(m·K) and 130 W/(m·K). The numerically and analytically performed calculations provide good estimations of the experimentally obtained data.

Composites made of carbon-fiber-reinforced carbon (C/C or CFC) are high-performance materials with a wide range of properties, making them especially suitable for the design of thermally and mechanically highly stressed components. As the production process of these high-performance materials is currently still very expensive, new concepts for an economical manufacturing process are required. This paper focusses on an innovative approach that uses the polymer-based pultrusion process for shaping with a subsequent carbonization step to C/C. In this process, carbon fibers (CF) and a phenolic resin were used to manufacture a semi-finished product made of unidirectional (UD) carbon-fiber-reinforced plastic (CFRP) with a fiber volume content of 66%. The C/C composite shows dimensional stability and has a flexural strength of approx. 240 MPa and a flexural modulus of approx. of 135 GPa with an elongation of 1.8%.

BackgroundConservative scoliosis therapy in the form of assisted physiotherapeutic scoliosis exercises is supplemented by self-contained training at home, depending on the approach (eg, Schroth, the Scientific Exercises Approach to Scoliosis). Complex exercises, lack of awareness of the importance of training, and missing supervision by therapists often lead to uncertainty and reduced motivation, which in turn reduces the success of home-based therapy. Increasing digitalization in the health care sector offers opportunities to close this gap. However, research is needed to analyze the requirements and translate the potential of digital tools into concrete solution concepts. ObjectiveThe aim of this study is to evaluate the potential for optimizing home-based scoliosis therapy in terms of motivation, assistive devices, and digital tools. MethodsIn collaboration with the Institute of Physiotherapy at the Jena University Hospital, a survey was initiated to address patients with scoliosis and physical therapists. A digital questionnaire was created for each target group and distributed via physiotherapies, scoliosis forums, the Bundesverband für Skoliose Selbsthilfe e. V. newsletter via a link, and a quick response code. The survey collected data on demographics, therapy, exercise habits, motivation, assistive devices, and digital tools. Descriptive statistics were used for evaluation. ResultsOf 141 survey participants, 72 (51.1%; n=62, 86.1%, female; n=10, 13.9%, male) patients with scoliosis with an average age of 40 (SD 17.08) years and 30 scoliosis therapists completed the respective questionnaires. The analysis of home-based therapy showed that patients with scoliosis exercise less per week (2 times or less; 45/72, 62.5%) than they are recommended to do by therapists (at least 3 times; 53/72, 73.6%). Patients indicated that their motivation could be increased by practicing together with friends and acquaintances (54/72, 75%), a supporting therapy device (48/72, 66.7%), or a digital profile (46/72, 63.9%). The most important assistive devices, which are comparatively rarely used in home-based therapy, included balance boards (20/72, 27.8%), wall bars (23/72, 31.9%), mirrors (36/72, 50%), and long bars (40/72, 55.6%). Therapists saw the greatest benefit of digital tools for scoliosis therapy in increasing motivation (26/30, 87%), improving home therapy (25/30, 83%), monitoring therapy progress (25/30, 83%), and demonstrating exercise instructions (24/30, 80%). ConclusionsIn this study, we investigated whether there is any potential for improvement in home-based scoliosis therapy. For this purpose, using online questionnaires, we asked patients with scoliosis and therapists questions about the following topics: exercise habits, outpatient and home-based therapy, motivation, supportive devices, and digital tools. The results showed that a lack of motivation, suitable training equipment, and tools for self-control leads to a low training workload. From the perspective of the patients surveyed, this problem can be addressed through community training with friends or acquaintances, a supportive therapy device, and digital elements, such as apps, with training instructions and user profiles.

In the field of adaptive building technologies, this research introduces the development of a self-regulating solar shading actuator that utilizes the thermal shape memory effect. The study focuses on addressing the actuator’s performance under diverse environmental conditions. Thermal simulations were carried out during the development of the individual components of the actuator and for the prediction of specific switching temperatures. The investigation includes an analysis of the sunshade’s response to varying environmental conditions, emphasizing its effectiveness on clear summer days and identifying challenges during overcast periods. The critical coordination between the solar collector and the shape memory alloy (SMA) wire is examined, shedding light on the impact of SMA temperature dynamics on the actuation performance. Through the integration of simulation data and real-world measurements, the study validates the thermal model for the solar collector, establishing the robustness of the system’s operation. This research work contributes significantly to the development of intelligent actuators and outlines the importance of validation of SMA-based applications under real conditions.

In revision operations, ceramic heads of modular hip implants can be replaced. As the surface of the stem taper can be damaged, additional adapter sleeves are applied. The components are usually connected manually by the surgeon in a one-step procedure by hammer impacts. In this study, we investigated a two-step joining procedure with reproducible impaction force. First, the adapter sleeve and head were joined quasi-statically with a force of 2 kN using an assembly device. In the second step, these components were applied to the stem taper using a pulse-controlled instrument. For reference, the joints were assembled according to standard conditions using a tensile testing machine. An average pull-off force of 1309 ± 201 N was achieved for the components joined by the instrument, and the average measured values for the components joined by the testing machine were 1290 ± 140 N. All specimens achieved a force >350 N when released and therefore met the acceptance criterion defined for this study. This study showed that a modified procedure in two steps with a defined force has a positive effect on the reproducibility of the measured joining forces compared to previous studies.

This paper presents a new approach to monitoring ultrasonic systems using structurally integrated piezoceramics. These are integrated into the sonotrode at different points and with different orientations. The procedure for integrating the piezoceramics into the sonotrode and their performance is experimentally investigated. We examine whether the measured signal can be used to determine the optimal operating frequency of the ultrasonic system, if integrating several piezoceramics enables discernment of the current vibration shape, and if the piezoceramics can withstand the high strains caused by the vibrations in a frequency range of approximately 20–25 kHz. The signals from the piezoceramic sensors are compared to the real-time displacement at different points of the sonotrode using a 3D laser scanning vibrometer. To evaluate the performance of the sensors, different kinds of excitation of the ultrasonic system are chosen.

Hip implants have a modular structure which enables patient-specific adaptation but also revision of worn or damaged friction partners without compromising the implant-bone connection. To reduce complications during the extraction of ceramic inlays, this work presents a new approach of a shape-memory-alloy-actuator which enables the loosening of ceramic inlays from acetabular hip cups without ceramic chipping or damaging the metal cup. This technical in vitro study exam-ines two principles of heating currents and hot water for thermal activation of the shape-memory-alloy-actuator to generate a force between the metal cup and the ceramic inlay. Mechanical tests concerning push-in and push-out forces, deformation of the acetabular cup according to international test standards, and force generated by the actuator were generated to prove the feasibility of this new approach to ceramic inlay revision. The required disassembly force for a modular acetabular device achieved an average value of 602 N after static and 713 N after cyclic loading. The actuator can provide a push-out force up to 1951 N. In addition, it is shown that the necessary modifications to the implant modules for the implementation of the shape-memory-actuator-system do not result in any change in the mechanical properties compared to conventional systems.

Modern hip implants have a modular design. In case of wear or other damage it allows surgeons to change the tribological partners, i.e., the acetabular liner and femoral ball. In both revision and primary surgery, the secure joining of the implant components is important for the success of the operation. The two components, namely the ceramic liner and hip cup, are connected via a conical press connection and should be concentrically aligned to avoid chipping. Malseated liners can reduce the life span in situ. The amount of the joining force, which is usually applied via a hammer, depends on the surgeon. In this study, an alternative joining method for acetabular ceramic liners in hip cups was investigated, which intends to make the process more reproducible and thus safer. For this purpose, a handpiece was used to apply a defined force impulse of 4 kN. For the concentric alignment of a ceramic liner in the hip cup, an adapter was developed based on findings via a qualitative finite element (FE) analysis. Insertion and pushout tests of the acetabular cup–liner connection were performed in the laboratory with the new instrument (handpiece with the connected adapter) to evaluate the functionality of the instrument and the reproducibility of the new insertion method. For comparison, liners and acetabular cups were joined using a testing machine according to the standard. The presented results demonstrate the technical proof-of-concept of the new joining method under laboratory conditions. They meet the acceptance criteria of established manufacturers, which proves the equivalency to proven methods for joining modular implant components. To verify the improvement of the new joining method compared to the conventionally used joining method, an application-oriented study with different surgeons and the new joining instrument under clinical conditions is necessary.

Abstract Background Demographic change is leading to an increase in the number of osteoporotic patients, so a rethink is required in implantology in order to be able to guarantee adequate anchoring stability in the bone. The functional modification of conventional standard screw implants using superelastic, structured Ti6Al4V anchoring elements promises great potential for increasing anchoring stability. Methods For this purpose, conventional screw implants were mechanically machined and extended so that structured-superelastic-positionable-Ti6Al4V anchoring elements could be used. The novel implants were investigated with three tests. The setup of the anchoring elements was investigated in CT studies in an artificial bone. In a subsequent simplified handling test, the handling of the functional samples was evaluated under surgical conditions. The anchorage stability compared to standard screw implants was investigated in a final pullout test according to ASTM F543—the international for the standard specification and test methods for metallic medical bone screws. Results The functionalization of conventional screw implants with structured superelastic Ti6Al4V anchoring elements is technically realizable. It was demonstrated that the anchoring elements can be set up in the artificial bone without any problems. The anchorage mechanism is easy to handle under operating conditions. The first simplified handling test showed that at the current point of the investigations, the anchoring elements have no negative influence on the surgical procedure (especially under the focus of screw implantation). Compared to conventional standard screws, more mechanical work is required to remove the functional patterns completely from the bone. Conclusion In summary, it was shown that conventional standard screw implants can be functionalized with Ti6Al4V-structured NiTi anchoring elements and the new type of screws are suitable for orthopedic and neurosurgical use. A first biomechanical test showed that the anchoring stability could be increased by the anchoring elements.

BackgroundThe electronic health record (EHR) targets systematized collection of patient-specific, electronically stored health data. The EHR is an evolving concept driven by ongoing developments and open or unclear legal issues concerning medical technologies, cross-domain data integration, and unclear access roles. Consequently, an interdisciplinary discourse based on representative pilot scenarios is required to connect previously unconnected domains. ObjectiveWe address cross-domain data integration including access control using the specific example of a unique device identification (UDI)–expanded hip implant. In fact, the integration of technical focus data into the hospital information system (HIS) is considered based on surgically relevant information. Moreover, the acquisition of social focus data based on mobile health (mHealth) is addressed, covering data integration and networking with therapeutic intervention and acute diagnostics data. MethodsIn addition to the additive manufacturing of a hip implant with the integration of a UDI, we built a database that combines database technology and a wrapper layer known from extract, transform, load systems and brings it into a SQL database, WEB application programming interface (API) layer (back end), interface layer (rest API), and front end. It also provides semantic integration through connection mechanisms between data elements. ResultsA hip implant is approached by design, production, and verification while linking operation-relevant specifics like implant-bone fit by merging patient-specific image material (computed tomography, magnetic resonance imaging, or a biomodel) and the digital implant twin for well-founded selection pairing. This decision-facilitating linkage, which improves surgical planning, relates to patient-specific postoperative influencing factors during the healing phase. A unique product identification approach is presented, allowing a postoperative read-out with state-of-the-art hospital technology while enabling future access scenarios for patient and implant data. The latter was considered from the manufacturing perspective using the process manufacturing chain for a (patient-specific) implant to identify quality-relevant data for later access. In addition, sensor concepts were identified to use to monitor the patient-implant interaction during the healing phase using wearables, for example. A data aggregation and integration concept for heterogeneous data sources from the considered focus domains is also presented. Finally, a hierarchical data access concept is shown, protecting sensitive patient data from misuse using existing scenarios. ConclusionsPersonalized medicine requires cross-domain linkage of data, which, in turn, require an appropriate data infrastructure and adequate hierarchical data access solutions in a shared and federated data space. The hip implant is used as an example for the usefulness of cross-domain data linkage since it bundles social, medical, and technical aspects of the implantation. It is necessary to open existing databases using interfaces for secure integration of data from end devices and to assure availability through suitable access models while guaranteeing long-term, independent data persistence. A suitable strategy requires the combination of technical solutions from the areas of identity and trust, federated data storage, cryptographic procedures, and software engineering as well as organizational changes.

The soft tissues of residual limb amputees are subject to large volume fluctuations over the course of a day. Volume fluctuations in residual limbs can lead to local pressure marks, causing discomfort, pain and rejection of prostheses. Existing methods for measuring interface stress encounter several limitations. A major problem is that the measurement instrumentation is applied in the sensitive interface between the prosthesis and residual limb. This paper presents the principle investigation of a non-intrusive technique to evaluate the fit of orthopaedic prosthesis sockets in transfemoral amputees based on experimentally obtained vibrational data. The proposed approach is based on changes in the dynamical behaviour detectable at the outer surface of prostheses; thus, the described interface is not affected. Based on the experimental investigations shown and the derived results, it can be concluded that structural dynamic measurements are a promising non-intrusive technique to evaluate the fit of orthopaedic prosthesis sockets in transfemoral amputee patients. The obtained resonance frequency changes of 2% are a good indicator of successful applicabilityas these changes can be detected without the need for complex measurement devices.

Abstract Hard finishing of gearings such as continuous generating gear grinding is highly essential for manufacturers due to increasing demands on gearboxes regarding quality and economical aspects, especially in the growing field of electric mobility. Here, high requirements on the acoustic behavior and low production cost come into conflict in the last stage of manufacturing gearings in a particular way. Against this background, in‐process evaluation methods for manufacturing processes are developed in order to reduce scrap parts and to exploit the process limits by collecting and processing of sensor signal data and by adapting measures based on reasonable process models. This investigation shows how the condition of abrasive tools and workpiece quality are evaluated by means of process near acoustic emission sensor application and motor current of the grinding spindle in order to adapt shifting and feed movement in generating gear grinding process. A calculation method based on a simulation process model is introduced to characterize relevant vibration frequency bands and the resulting acoustically effective waviness on tooth flanks, depending on workpiece and process parameters. Appropriate adaption of the grinding process for increasing productivity while maintaining workpiece quality is based on the findings of an intelligent in‐process evaluation.

Prosthesis treatment requires the close interaction of different actors. In fitting prostheses to patients, special attention is given to the manufacturing of the socket. The continuous development of the technologies involved in the fitting and optimization of prostheses is shown in the literature. The assessment of orthopedic technicians and their influence in the process is thus far largely unexplored. Ten orthopedic technicians were interviewed about the socket fitting process after transfemoral amputation. The research goal was to clarify the socket treatment process with regards to the German context. The results showed that the orthopedic technicians focussing on the patient during the fitting process. This study underlines the importance of interaction and empathy. Volume fluctuations are decisive within the treatment process and are interactively influenced by various factors. Furthermore, the research emphasizes the need for appropriate assistive technologies and the potential for the further development of existing systems.

Additive manufacturing is establishing new forms of manufacturing processes to produce functional parts. It is thus seen as a hope for a shift towards decentralised production and the associated positive effects on the environment. The most widespread process, Fused Filament Fabrication, already impresses with a large variety of materials and the possibility of including non-polymeric additives as fibre materials. To support this development, this paper describes a form of wire implementation as an add-on for existing FFF systems, that can be realised without major changes to hardware or software. The aim is to integrate electrical functions directly into the component - in one manufacturing process. The process is based on a hybrid material made of PLA with a copper core, which was developed in advance. Within this work, two retrofittable units for FFF printers are described, which cut a continuous wire with a diameter of $0.2~mm$ embedded in a polymer in a fully automatic manner. Furthermore, two thermal contacting processes are presented, which make it possible to contact the embedded wire via the heated extruder nozzle and metallic inserts. Thereby, a best contact resistance of 0.009 ± $0.0023~\Omega$ (50% confidence interval) could be achieved for a screw contact. For a plug-in or solder contacts, a contact resistance of 0.059 ± $0.028\Omega$ (50% confidence interval) was realised. In terms of process technology, the wire deposition within the plastic structure could be reliably realised at printing speeds of $10~mm/s$ on straight sections and $1~mm/s$ in curves with a radius of $5~mm$ . The developed process was successfully validated using a functional demonstrator. The functional sample can be selectively heated to the glass transition temperature and reversibly formed. In summary, the developed methods are suitable for cost-effectively expanding existing FFF systems to integrate electrical functions during the 3D printing process.

This paper presents a new approach to the structural integration of piezoceramics into thin-walled steel components for condition-monitoring applications. The procedure for integrating the sensors into metal components is described, and their functionality is experimentally examined with a 2 mm-thick steel sheet. The signal quality of the produced sensors is investigated in a frequency range from 100 Hz to 50,000 Hz and is compared with the results of piezo patches and strain gauges under the same conditions. The results show that due to a higher signal-to-noise ratio and a better coherence, the structurally integrated piezoceramics and the piezo patches are more qualified sensors for vibration measurement in the examined frequency range than the strain gauges. The measurements also indicate that the patches provide higher amplitudes for the frequency range up to 20 kHz. Beyond that, up to 40 kHz, the integrated sensors supplied higher amplitudes. The better signal quality in different frequency ranges as well as the different manufacturing and application methods can be interpreted as an advantage or disadvantage depending on the boundary conditions of the condition-monitoring system. In summary, structural integrated piezoceramics extend the options of monitoring technology.

Thermal switches contribute to efficient and safe thermal management of components and overall systems in various technical applications by actively controlling heat transfer in response to varying thermal loads and ambient conditions. Heat pipes are passive heat transfer devices constituting an integral part of various thermal management systems such as in spacecraft or consumer electronics thermal control. Heat pipes also form a promising approach for thermal switches due to their high effective thermal conductivity. In this paper, a wickless copper-water heat pipe based thermal switch with an electromagnetic linear actuator is presented. The magnetically actuated motion of a plunger integrated into the heat pipe affects the latent heat transport cycle leading to a switchable heat transfer. Thermal measurements conducted to determine the total thermal resistance of the heat pipe demonstrate the efficacy of the thermal switch. It was found that the thermal resistance of the heat pipe was increased by up to 53% in off state while the heat pipe performance in on state was not significantly affected by the integrated mechanism.

With a growing number of electronic devices surrounding our daily life, it becomes increasingly important to create solutions for clear and simple communication and interaction at the human machine interface (HMI). Haptic feedback solutions play an important role as they give a clear direct link and response to the user. This work demonstrates multifunctional haptic feedback devices based on fully printed piezoelectric transducers realized with functional polymers on thin paper substrate. The devices are flexible; lightweight and show very high out-of-plane deflection of 213 µm at a moderate driving voltage of 50 Vrms (root mean square) achieved by an innovative multilayer design with up to five individually controllable active layers. The device creates a very clear haptic sensation to the human skin with a blocking force of 0.6 N at the resonance frequency of 320 Hz, which is located in the most sensitive range of the human fingertip. Additionally the transducer generates audible information above two kilohertz with a remarkable high sound pressure level. Thus the paper-based approach can be used for interactive displays in combination with touch sensation; sound and color prints. The work gives insights into the manufacturing process; the electrical characteristics; and an in-depth analysis of the 3D deflection of the device under variable conditions

The technique joining by forming allows the structural integration of piezoceramic fibers into locally microstructured metal sheets without any elastic interlayers. A high-volume production of the joining partners causes in statistical deviations from the nominal dimensions. A numerical simulation on geometric process sensitivity shows that the deviations have a high significant influence on the resulting fiber stresses after the joining by forming operation and demonstrate the necessity of a monitoring concept. On this basis, the electromechanical behavior of piezoceramic array transducers is investigated experimentally before, during and after the joining process. The piezoceramic array transducer consists of an arrangement of five electrical interconnected piezoceramic fibers. The findings show that the impedance spectrum depends on the fiber stresses and can be used for in-process monitoring during the joining process. Based on the impedance values the preload state of the interconnected piezoceramic fibers can be specifically controlled and a fiber overload.

Abstract Background The modularity in total hip arthroplasty (THA) allows orthopaedic surgeons for an exact reconstruction of hip biomechanical parameters especially in revision and tumor arthroplasty. Modular structured femoral stems using taper junctions showed increased implant breakage in the recent past. Presentation of the hypothesis We hypothesize that a novel modular stem-neck-interface leads to less implant breakage compared to conventional femoral stems. Testing of the hypothesis For this purpose, a novel modular femoral stem for THA was to design and manufacture. Therefore, three different variants of interface mechanisms were developed that enable a simple connection between the stem and the neck modules and allow for intra-operatively adjustment. Three prototypes A, B and C were manufactured and subsequently dynamic fatigue (ISO 7206–6) and body donor tested. Implication of the hypothesis Modularity in THA is mainly applied in THA as well as in revision and tumor arthroplasty. Modular implants are barely used because of the high risk of breakage. Another risks in this context are taper fretting, corrosion and disconnection. With the novel design, it should be possible to detach the stem and neck module intra-operatively to adapt the anatomical situation. The novel coupling mechanism of the rotating interface seems to be the most suitable for a secure stem-neck connection and is characterized by good intraoperative handling.

Nowadays, every large enterprise is concerned about reducing CO2 emissions. Along with legislation, management, packaging, and transportation decisions, optimising the operation of automated systems in the industry is important. Overheating processes or large cooling systems of one machine during product assembly may seem minor but at the industry level it is quite significant. Either an optimisation of cooling systems or an intelligent machine control which will prevent heat strokes and allow the transition to passive cooling of the whole system is an important issue for improving machine tools efficiency and contributing therefore to CO2 reduction in the industry sector. This research is a transitional phase from the creation of a control system to solve the problems of resonance in the control of systems with parallel piezo kinematics, which were designed to automate the iterative process of non-circular drilling with a precise shape and the subsequent research on the implementation of smart control to optimise the cooling of industrial machines. The total dynamics of the example system in this research is unknown and consists of the dynamics of electrical converters, piezo kinematics, and mechanics. The control signal of this system is generated by the model of the system state with assumptions and simplifications in combination with machine learning techniques considering the previous errors of the transient characteristics with the possibility of re-drilling without damaging the workpiece and with possibility of further trainings to eliminate the iterative process in general. Algorithms for further training at different resonances with a drilling depth change for cylinders of internal combustion engines are offered. These algorithms are proposed for accurate transmission of the input signal amplitude even in resonant situations, power optimisation, increase the system efficiency, as well as reducing the carbon footprint when used in industry in specific applications.

The aim of this study was to investigate the mechanical behavior, and the microstructure of NiTiCu shape memory alloy wires joined with silver-coated copper ferrules via ultrasonic spot welding. Therefore, the electrical resistance was measured during tensile testing, and the joints were analyzed by scanning electron microscopy. Energy-dispersive X-ray spectroscopy has determined the compounds of the developed welding zones. Furthermore, the influence of the ultrasonic welding on the transition temperatures of the NiTiCu wires was examined via differential scanning calorimetry. Tensile tests have shown that the ultimate tensile strengths of the joints reached almost 100% of that of the base material. An additional heat treatment rebuilt the typical shape memory alloy behavior after the ultrasonic welding process detwinned the martensitic wires. In addition, the B19′ structure of the welding zone and the ultrasonic spot-welding process did not affect the transition temperatures of the shape memory alloy.

Minimally invasive surgery is increasingly used in many medical operations because of the benefits for the patients. However, for the surgeons, accessing the situs through a small incision or natural orifice comes with a reduction of the degrees of freedom of the instrument. Due to friction of the mechanical coupling, the haptic feedback lacks sensitivity that could lead to damage of the tissue. The approach of this work to overcome these problems is to develop a control concept for position control and force estimation with shape memory alloys (SMA) which could offer haptic feedback in a novel handheld instrument. The concept aims to bridge the gap between manually actuated laparoscopic instruments and surgical robots. Nickel-titanium shape memory alloys are used for actuation because of their high specific energy density. The work includes the manufacturing of a functional model as a proof of concept comprising the development of a suitable forceps mechanism and electronic circuit for position control and gripping force measurement, as well as designing an ergonomic user interface with haptic force feedback.

The demographic change in and the higher incidence of degenerative bone disease have resulted in an increase in the number of patients with osteoporotic bone tissue causing. amongst other issues, implant loosening. Revision surgery to treat and correct the loosenings should be avoided, because of the additional patient stress and high treatment costs. Shape memory alloys (SMA) can help to increase the anchorage stability of implants due to their superelastic behavior. The present study investigates the potential of hybridizing NiTi SMA sheets with additively manufactured Ti6Al4V anchoring structures using laser powder bed fusion (LPBF) technology to functionalize a pedicle screw. Different scanning strategies are evaluated, aiming for minimized warpage of the NiTi SMA sheet. For biomechanical tests, functional samples were manufactured. A good connection between the additively manufactured Ti6Al4V anchoring structures and NiTi SMA substrate could be observed though crack formation occurring at the transition area between the two materials. These cracks do not propagate during biomechanical testing, nor do they lead to flaking structures. In summary, the hybrid manufacturing of a NiTi SMA substrate with additively manufactured Ti6Al4V structures is suitable for medical implants.

The wear comfort of a prosthesis is of great importance for amputee patients. The wear comfort can be affected by changes in the interface between the residual limb and prosthesis socket, which can be caused by time-dependent volume fluctuations of the tissue, leading to unwanted local pressure marks. The basis to ensure time-independent wear comfort of a prosthesis is to identify these changes. Common techniques for identifying these variations have a negative impact on the sensitive interface between the residual limb and prosthesis. The following paper contains a proof of concept for the detection of local pressure marks without affecting the described interface using structural dynamics measurements, exemplarily shown at a prosthetic socket for transfemoral amputees in a test bench scenario. The dynamical behaviour of the investigated system is analysed in the form of frequency response functions acquired for different pressure locations and preloads using an impact hammer for excitation and a triaxial acceleration sensor. The frequency response functions show major changes for the various boundary conditions with respect to their frequency-dependent compositions. The results demonstrate how the utilised method enables the identification of changes in local pressure marks regarding the variation of position and magnitude.

The current article proposes a concept for the additive manufacturing of rubber components using extrusion-based 3D printing, in which an additional medium is added to ensure the maintenance of shape within the elastomeric structure during the additive manufacturing process and in the subsequent vulcanization process. Specific requirements for the dimensional stabilization of the media were defined and suitable media were derived. Silicone rubber, molding sand, and plaster were examined in experimental vulcanization tests for their suitability as possible media with regard to shape retention. Selected rubber geometries made of NBR were embedded in these media to undergo the vulcanization process. The results show a significant influence of the media on the heating times. All media were able to ensure that the rubber geometries maintained their shape during vulcanization. Nevertheless, some side effects were found. The silicone rubber did not cure properly around the rubber sample. Therefore, it was difficult to remove it from the rubber after vulcanization. The molding sand caused an increased surface roughness on the rubber. Plaster changed the glossy surfaces at the beginning to a matte one after vulcanization and residuals were difficult to remove. However, all media can serve as stabilization media with specific changes.

The dissemination and use of additive processes are growing rapidly. Nevertheless, for the material class of elastomers made of vulcanizable rubber, there is still no technical solution for producing them using 3D printing. Therefore, this paper deals with the basic investigations to develop an approach for rubber printing. For this purpose, a fused deposition modeling (FDM) 3D printer is modified with a screw extruder. Tests are carried out to identify the optimal printing parameters. Afterwards, test prints are performed for the deposition of rubber strands on top of each other and for the fabrication of simple two-dimensional geometries. The material behavior during printing, the printing quality as well as occurrences of deviations in the geometries are evaluated. The results show that the realization of 3D rubber printing is possible. However, there is still a need for research to stabilize the layers during the printing process. Additionally, further studies are necessary to determine the optimum parameters for traverse speed and material discharge, especially on contours.

This article describes a mathematical model simplification, designed to automate the iterative process of non-circular drilling with a precise shape. This model has been optimized for systems that already have experimental data for processing and analysis. Additionally, using optimization steps, the model can be used for systems with insufficient experimental data with a self-learning opportunity. The high-end model can be used for drilling systems represented as a “black box” without knowing of any parameters of the system. The simplification and assumptions algorithm is based on controlling the input signal for non-circular drilling in the cylinders of internal combustion engines using a drilling machine controlled by 8 piezoelectric actuators. The total dynamics of this system is unknown and consists of the dynamics of electrical converters, piezo-kinematics, and mechanics. Simplification is carried out starting from the methods of diacoptics for a complex system with different process-flow rates, and ending with one or the sum of linear models valid for a given system of assumptions.

Many living beings show the ability and necessity to develop invertible, tubular structures to enable additional functions temporarily. The biological archetypes always demonstrate a high change of volume of the structure between an inactive and active state. This makes the principle interesting for many technical applications, where a certain geometry or an additional volume has to be generated situationally for a task and can only be accepted temporarily, for example, in minimally invasive robotics. A possibility was sought to transfer the archetype into the technical context and to evaluate geometric-constructive dependencies based on an inversion of the structure. The result is a practicable design for repeatedly invertible net structures, which can be used for products with temporary additional functions and volumes.

Magnetostrictive materials are a group of smart materials with comparable properties to piezoelectric materials regarding strain and operating frequency. In contrast, the Curie temperature is much higher and the principle effect allows different actuator designs. Especially in the case of rotating actuators in ultrasonic assisted machining, a high potential is seen for a simplified energy transmission. In the study, a test stand for a rotating actuator with simultaneous vibration in longitudinal direction was designed to show the proof of principle for this idea. It was shown that the current inducing the magnetic field as well as its frequency influence the amplitude of the rotating actuator. This is a first step to developing a rotating actuator for ultrasonic machining.

The potential of adaptronic applications has been proven in many conceptual studies. A broad use in high-efficiency branches is often hindered by the absence of an appropriate assembly method. Especially for piezoceramic foil transducers, the application on structural parts can be simplified using a semi-finished part that includes the transducer. The part is then shaped in a final forming operation. The purpose of the present study is the investigation of process limits in automated process chains for producing semi-finished parts. An adhesive is used in the process, which is only locally cured. This bi-conditioned state is achieved using cooling and heating elements. The process limits are mainly affected by the choice of temperature and curing time between adhesive application and forming operation. Several tests with a rotational rheometer were carried out to investigate the curing behavior. An appropriate process window was identified varying processing time and temperature. The results were then used to build a model of the curing behavior. A mathematical approach had to be used to find the best configuration because no sharp border exists between the two adhesive conditions of liquid and solid state. The process parameters were proven with runs inside and outside of the process limits.