Abstract: A method for processing a three-dimensional (3D) mesh model includes receiving a 3D mesh model. One or more regions including a potential sharp cusp are automatically detected. The automatically detected one or more regions are displayed to a user and an active region of the 3D mesh model is defined by the user. Sphere fitting and Laplacian smoothing are applied to the designated active region to remove a sharp cusp therefrom and to obtain a modified 3D mesh model.

Abstract: Methods for structure preserving topology optimization of lattice structures for additive manufacturing. A method includes receiving an initial lattice model, a physical objective of the initial lattice model to be optimized, forces to be applied to the initial lattice model and their respective locations, and an optimal volume ratio for an optimized lattice model, computing a bounding box of the initial lattice model and an axis-aligned voxel grid, computing an implicit scalar field representation of an initial volume ratio of the initial lattice model, mapping the loads to their respective locations in the axis-aligned voxel grid, performing an additive topology optimization on the initial lattice model to create the optimized lattice model until the initial volume ratio satisfies the optimal volume ratio, and storing the optimized lattice model.

Abstract: A computer-implemented method for computing ridges and valleys of a height field includes a computing platform receiving a plurality of sample points associated with a dataset and an indication of an orientation for referencing the plurality of sample points and applying an interpolation function to the plurality of sample points to determine the height field. The computing platform selects a plurality of seed points associated with the height field and calculates a Hessian matrix of the height field. The Hessian matrix is used by the computing platform to trace (a) one or more ridge curves associated with the height field and (b) one or more valley curves associated with the height field using the plurality of seed points.

Abstract: The design process for the surgical plan in orthopedics and/or the design of a personalized cutting guide and/or implant are automated in a workflow frame work. Abstracted rules are scripted through a sequence of operations to alter a bone surface or model for fitting an implant. Using bone information for a specific patient, the proper implant and series of cuts are determined using the rules. A corresponding cutting guide may be fitted to the bone information for the specific patient. Surgical planning of bone replacement implants is performed automatically.

Abstract: A computer-implemented method of optimized lattice partitioning of solid 3-D models for additive manufacturing includes a computer receiving a 3-D model of an object to be printed and functional specifications indicating desired mechanical properties for portions of the object. The computer generates a plurality of lattice template structures based on the 3-D model and a uniform grid structure of an internal surface of the object. The computer determines material behaviors for each of the plurality of lattice template structures using the functional specifications and assigns the lattice template structures to locations in the uniform grid structure based on the material behaviors of the lattice template structures, thereby yielding a printable lattice.

Abstract: A method for designing a personalized medical device includes receiving a template design of a medical device. An image including a patient anatomical geometry is acquired. The template design is combined with the image including the patient anatomical geometry to create a custom medical device design. A region of interest encompassing the sharp concave edge is automatically identified within the custom medical device design using one or more seed points received from a user. Surface smoothing of the custom medical device design is performed within the region of interest to bolster a thickness of the custom medical device design. A 3D-printable model is obtained from the surface smoothed custom medical device design.

Abstract: A computer assisted method creates accurate CAD/CAM models of custom orthopedic implants is provided. Information about bone geometry is acquired through medical imaging such as CT image scans. The desired bone surface region is extracted as a polygonal mesh after processing the 3D images. A smooth and accurate B-Spline surface is fitted to the polygonal mesh that is thickened to a solid CAD model. A patient-specific customized implant is manufactured from the obtained CAD model. The patient-specific customized implant is implanted in a patient by a surgeon in an operating room. A processor based system to generate a CAD/CAM file of the patient-specific customized implant and a manufacturing system enabled to manufacture the implant from the CAD/CAM file are also disclosed.

Abstract: A computer-implemented method for optimizing manufacturing of a product based on total life cycle energy consumption includes receiving manufacturing parameters associated with manufacturing the product according to a manufacturing process and a candidate hybrid manufacturing plan for implementing the manufacturing process using a first combination of additive manufacture techniques and non-additive manufacture techniques. An energy consumption dataset is generated comprising (i) first energy consumption data corresponding to a non-additive manufacturing process, (ii) second energy consumption data corresponding to an additive manufacturing process, and (iii) energy intensity data associated with manufacturing materials. Next, the total life-cycle energy consumption for the candidate hybrid manufacturing plan is computed.

Abstract: A computer-implemented method for computing ridges and valleys of a height field includes a computing platform receiving a plurality of sample points associated with a dataset and an indication of an orientation for referencing the plurality of sample points and applying an interpolation function to the plurality of sample points to determine the height field. The computing platform selects a plurality of seed points associated with the height field and calculates a Hessian matrix of the height field. The Hessian matrix is used by the computing platform to trace (a) one or more ridge curves associated with the height field and (b) one or more valley curves associated with the height field using the plurality of seed points.

Abstract: A computer-implemented method for ranking design parameter significance includes a computer receiving an input dataset representative of a physical object. This input dataset includes a baseline parameters and associated probabilities. The computer also receives performance requirements. For each respective baseline parameter, the computer performs an analysis process. During this analysis process, a range of parameter values are selected for the respective baseline parameter based on its corresponding probability distribution. The range of parameter values are segmented into parameter subsets and multiple instances of a simulation are executed using the performance requirements to yield snapshots. A Proper Orthogonal Decomposition (POD) basis is derived using the snapshots. A sensitivity analysis is performed based on the POD basis to yield a sensitivity measurement representative of an effect of variation of the respective parameter on the performance requirements.

Abstract: Methods for computer-aided simulation of multi-layer selective laser sintering and melting additive manufacturing processes and corresponding systems and computer-readable mediums. A method includes receiving a solid model. The method includes slicing the solid model geometry along a build direction and creating 3D meshes that represent manufacturing layers. The method includes simulating manufacture of each of the 3D meshes to produce corresponding deformed 3D meshes. The method includes building a 3D mesh model from the deformed 3D meshes. The method includes displaying the 3D mesh model.

Abstract: Methods for product data management and corresponding systems and computer-readable mediums. A method includes receiving a solid model. The method includes analyzing the solid model to determine a suggested orientation that minimizes a build height or minimizes a support volume. The method includes displaying and saving the suggested orientation.

Abstract: A method for processing a three-dimensional (3D) mesh model includes receiving a 3D mesh model. One or more regions including a potential sharp cusp are automatically detected. The automatically detected one or more regions are displayed to a user and an active region of the 3D mesh model is defined by the user. Sphere fitting and Laplacian smoothing are applied to the designated active region to remove a sharp cusp therefrom and to obtain a modified 3D mesh model.

Abstract: A method for designing a personalized medical device includes receiving a template design of a medical device. An image including a patient anatomical geometry is acquired. The template design is combined with the image including the patient anatomical geometry to create a custom medical device design. A region of interest encompassing the sharp concave edge is automatically identified within the custom medical device design using one or more seed points received from a user. Surface smoothing of the custom medical device design is performed within the region of interest to bolster a thickness of the custom medical device design. A 3D-printable model is obtained from the surface smoothed custom medical device design.

Abstract: A computer assisted method creates accurate CAD/CAM models of custom orthopedic implants is provided. Information about bone geometry is acquired through medical imaging such as CT image scans. The desired bone surface region is extracted as a polygonal mesh after processing the 3D images. A smooth and accurate B-Spline surface is fitted to the polygonal mesh that is thickened to a solid CAD model. A patient-specific customized implant is manufactured from the obtained CAD model. The patient-specific customized implant is implanted in a patient by a surgeon in an operating room. A processor based system to generate a CAD/CAM file of the patient-specific customized implant and a manufacturing system enabled to manufacture the implant from the CAD/CAM file are also disclosed.

Abstract: Methods for structure preserving topology optimization of lattice structures for additive manufacturing. A method includes receiving an initial lattice model, a physical objective of the initial lattice model to be optimized, forces to be applied to the initial lattice model and their respective locations, and an optimal volume ratio for an optimized lattice model, computing a bounding box of the initial lattice model and an axis-aligned voxel grid, computing an implicit scalar field representation of an initial volume ratio of the initial lattice model, mapping the loads to their respective locations in the axis-aligned voxel grid, performing an additive topology optimization on the initial lattice model to create the optimized lattice model until the initial volume ratio satisfies the optimal volume ratio, and storing the optimized lattice model.

Abstract: Methods for creating three dimensional lattice structures in computer-aided design models. A method includes receiving a solid model containing a plurality of boundary surfaces for a void region, computing a bounding box of the solid model and a plurality of grid points on an axis-aligned grid within the bounding box, creating a lattice cell layout for a lattice structure within the void region, computing an implicit model defined by a scalar value for each of the grid points on the axis-aligned grid, extracting the lattice structure in the solid model based on the implicit model.

Abstract: A method on a processor customizes a fixation plate for repairing a bone fracture. A digital CAD model of an implant contains smooth analytic geometry representations including NURBS. The CAD geometry is directly manipulated to generate a customized implant CAD model that conforms to the desired region of the bone surface of a patient. Direct manipulation of NURBS geometry is computationally fast and suitable for interactive planning. The patient specific customized implant is produced directly from the generated customized CAD model with a standard CNC machine before surgery. The patient customized implant is implanted in the patient.

Abstract: A method on a processor customizes a fixation plate for repairing a bone fracture. A digital CAD model of an implant contains smooth analytic geometry representations including NURBS. The CAD geometry is directly manipulated to generate a customized implant CAD model that conforms to the desired region of the bone surface of a patient. Direct manipulation of NURBS geometry is computationally fast and suitable for interactive planning. The patient specific customized implant is produced directly from the generated customized CAD model with a standard CNC machine before surgery. The patient customized implant is implanted in the patient.

Abstract: The design process for the surgical plan in orthopedics and/or the design of a personalized cutting guide and/or implant are automated in a workflow frame work. Abstracted rules are scripted through a sequence of operations to alter a bone surface or model for fitting an implant. Using bone information for a specific patient, the proper implant and series of cuts are determined using the rules. A corresponding cutting guide may be fitted to the bone information for the specific patient. Surgical planning of bone replacement implants is performed automatically.