3D-Modelling and casting simulation for the fabrication of megaprostheses implant by vacuum centrifugal casting

Recently, a high number of bone fracture incidents per year urges researchers in developing megaprostheses as artificial body parts. However, the complicated design and requirements for this custom-made prostheses are the key challenge. In accordance, this study focused on the preparation steps of 3D-modelling and casting simulation for the fabrication of megaprostheses implant by vacuum centrifugal casting. The reconstruction steps of 3D-modelling were started by observing the medical image data (i.e. CT-scan images). As the 3D-modelwas ready, the gating system was designed by placing two mandible bone models as the casting part with sprue and ingates where the design was respected to the gating system design for centrifugal casting. Moreover, the variation of casting part position,numbers, shapes and dimensions of the ingate, as well as the total surface area of ingates (Si) was applied while creating the gating system designsfor casting simulation. Chemically Pure Titanium (CP-Ti) with the pouring temperature and time of 1700°C and 4s, respectively, were used as the parameters for casting simulation. The solidification test results showed that the shrinkage cavities tended to decrease in volumetric scale with increasing the total surface area of the ingates, while the casting part position, number, shape, and dimension of ingate showed the difference in effectivity of the solidification of molten metal on the shrinkage cavities formation.