D5.6 Design of New AM solutions for MAD body fitting parts

Present document extends the previous concept of the New AM solutions for MAD body fitting parts. It constitutes the Deliverable D5.6, which is the output of Task 5.3 before the physical realization of the prototype of the novel machine of AM for MAD body fitting parts. It was preceded by deliverable D5.5 where some technical aspects have already been introduced and will therefore be excluded for readability and focus. This report considers a New AM machine design in the context of the project's target realization of MAD, in particular for the body fitting part. According with the overall consortium consensus, the priorities exploitable outcome from the project are: 1. KAFO(knee ankle foot orthosis) 2. AFO (ankle foot orthosis) 3. Complete exoskeleton This document will define the final design of the machine that will handle the manufacturing of the parts (of these structures) that will be in contact with the body. Starting from D5.5 specifications the final design of the machine prototype is hereafter presented. The document is structured as follows: Section 3 presents the Design of the AM Machine for BFP (for Body Fitting Parts), particularly discussing: Machine overall architecture design, divided into: o Machine upper part: portal design o Machine bottom part design Mixed material pellet based extruding Heated Chamber and build plate Section 4 briefly discusses preliminary details on Software Design and Automation system.