D 3.2 - Report on enhanced microEDM technologies and methods for model fabrication

The fabrication of personalized implants, tailored on patient needs, is a key issue for the future of several surgical fields. The presence of a prototyping service inside the hospital would be an added value for improving clinical activity. In this context, micro-Electro Discharge Machining is exploited to customize fixation devices in orthopedic surgery. An overview of the main devices is carried out in order to identify the main characteristics and to define the common fixation system specifications. The experimentation includes a technological evaluation of the proper micro-EDM technology, chosen according to the final design of the components. Two materials are investigated for the device fabrication: titanium and Si3N4-TiN ceramic composite. An optimization of the main technological parameters is performed in order to maximize the material removal rate ensuring the accuracy of the micro-features required. Finally, a test case is selected in order to evaluate the entire fabrication process chain.