Rapid development and manufacture of titanium implants for patients with large cranial defects.

This paper will review the application of digital reverse engineering to the design and manufacture of titanium implants for patients with large cranial defects. Traditionally this manufacturing process relied on extensive manual skills with an associated protracted cycle time / lead time and high cost. This research analysed the processes deployed in the manufacture of titanium cranial implants and replicated them using 3D CAD modelling and computer numerically controlled (CNC) manufacturing techniques.Advantages associate with this reverse engineering methodology include rapid 3D design of the implant and by utilising e-drawings obtaining collaborative approval of the design prior to manufacture. All associated tooling was designed on CAD and manufactured using CNC machine tools. This method facilitated increased precision of the resulting titanium components with substantial manufacturing lead time reduction and cost savings.The design processes have been dimensionally verified, manufacturing processes developed and the manufactured implants are being used within a number of neurosurgery departments in Ireland.