Innovative Developments in Virtual and Physical Prototyping Proceedings of the 5th International Conference on Advanced Research in Virtual and Rapid Prototyping, Leiria, Portugal, 28 September - 1 October, 2011

Innovative Developments in Virtual and Physical Prototyping presents essential research in the area of Virtual and Rapid Prototyping. The volume contains reviewed papers presented at the 5th International Conference on Advanced Research in Virtual and Rapid Prototyping, hosted by the Centre for Rapid and Sustainable Product Development of the Polytechnic Institute of Leiria, Portugal, from September 28 to October 1, 2011. A wide range of topics is covered, such as CAD and 3D Data Acquisition Technologies, Additive and Nano Manufacturing Technologies, Rapid Tooling & Manufacturing, Biomanufacturing, Materials for Advanced Manufacturing Processes, Virtual Environments and Simulation, Applications of Virtual and Physical Prototyping Technologies. Innovative Developments in Virtual and Physical Prototyping is intended for engineers, designers and manufacturers who are active in the areas of mechanical, industrial and biomedical engineering.

1. Keynotes Idea2Product Lab™ – A low cost alternative to introduce AM in South Africa Additive Manufacturing-assisted scaffold-based Tissue Engineering 2. Biomanufacturing Ultrastructural analysis of the hDSC interactions with biodegradable 3D scaffolds Individual contour adapted functional implant structures in Titanium New approaches to prototype 3D vascular-like structures by additive layer manufacturing A novel protein-based scaffold with macro- and micro-structural features for tissue engineering applications Surgical training and post-surgery evaluation using rapid prototyped biomodels The calibration of continuous Digital Light Processing (cDLP) for the highly accurate additive manufacturing of tissue engineered bone scaffolds Fabrication and characterization of biodegradable composite scaffolds for Tissue Engineering Spatially varying porosity with continuous path plan for hollowed tissue scaffolds Heterogeneous tissue scaffolds for spatiotemporally controlled release kinetics Medical application of rapid prototyping in orthopedics surgical planning Polycaprolactone-based scaffold plus BMP-2 in a sheep thoracic spine fusion model Development of functional graded device of PCL/PG by Selective Laser Sintering for drug delivery applications Flexible PCL tube scaffolds by winding of micro-extruded filaments Automation design and simulation of a stent Production and in-vitro characterization of micro-structured implant surfaces A study of mechanical and biological behavior of porous Ti6Al4V fabricated on EBM Enabling technologies for robotic organ printing The semi-automated design & manufacture of patient-specific intervertebral disc implants Additive manufacturing of soft tissue geometries for reconstruction purposes Development of patient-specific implants using Direct Metal Laser Sintering in Titanium 3. CAD and 3D Data Acquisition Technologies A prototype of a spherical tippe top An innovative methodology for laser scanner integration in a robot cell for small batch production of sculpture artworks Application of time compression techniques to dental restoration: A procedure for quality evaluation Reverse engineering of casting equipment for process simulation Patient specific parametric geometric modelling of cementless hip prosthesis Cross-section morphological study Cellular structure design for lightweight components "No models, no moulds!" Touchless gesture user interface for 3D visualization using the Kinect platform and open-source frameworks Multi-material blending for complex-shaped heterogeneous objects Gaussian Vault geometry: Integrated approach in design and fabrication of physical prototypes Application of contour tracing algorithm for assisting non-contact data acquisition Image-based direct slicing of a single line drawing for rapid prototyping Design and additive manufacturing of cellular lattice structures The Corinthian capital according to Alberti: Generative modelling and digital prototyping of classical architectural elements Evaluation of different fitting algorithms using CMM and white fringe projection systems Robust STL processing for extrusion-based manufacturing 4. MaterialsA review of different techniques to characterise the mechanical properties of SLS parts – focus on resistivity measurements Influence of hygrothermal aging on the mechanical properties of Nylon 12 composites processed by selective laser sintering Structural and functional properties of NiTi shape memory alloys produced by Selective Laser Melting Investigation on the inclusions in maraging steel produced by Selective Laser Melting SMARTerials for high performance buildings Porous ceramic filters through 3D printing Production of alumina parts through Selective Laser Sintering of alumina-polyamide composite powder Material characterisation of Additive Manufacturing components made from a polyetherketone (PEK) high temperature thermoplastic polymer Material study of laser cladded Inconel 625 A preliminary investigation on Selective Laser Melting of M2 high speed steel Fatigue behavior of additive manufacturing parts. A preliminary analysis Characterisation of carbon fibre reinforced nylon-12 composites for selective laser sintering process New material development for laser additive manufacturing Mechanical behavior of Epoxy-Aluminum composite for rapid tools applications Thermal characterization of laser sintering of nylon-12 Metallurgical, accuracy and cost analysis of Ti6Al4V dental coping fabricated by electron beam melting process Thermal and dynamic-mechanical behavior of Fullcure 3D Printing Resin post-cured by different methods Rheological study of poly vinyl alcohol with two thermo-initiator for use in rapid prototyping 5. Rapid Tooling & Manufacturing A study on the mouldability of technical parts using hybrid moulds and structural foams Rapid tooling in metal forming processes using 3D-printed tools Conformal cooling in moulds with special geometry Thermoplastic Resin Transfer Moulding in a rapid manufactured mould A creative solution for rapid and inexpensive model-making in product design processes Fabrication of a Biopsy Micro-Forceps prototype with Incremental Sheet Forming Using additive manufactured tooling in the fabrication of poly (L-Lactide-co-Glycolide) implants Developing Ti jewelry through additive manufacturing and conversion technologies Automation for building manufacturing 6. Additive and Nano Manufacturing Technologies Optimization of Selective Laser Melting technology using design of experiments method From functional specifications to optimized CAD model: Proposition of a new DFAM methodology A novel approach to produce Functionally Graded Materials for additive manufacturing Electrochemical micromilling with ultra short pulses Functionally Graded Rapid Prototyping Continuous contour printing versus layer by layer printing in an Additive Manufacturing Technology Methodology for analyzing the depth of sintering in the building platform Influence of process parameters in the first melting layer of a building platform in a SLM machine Surface finishing techniques for SLM manufactured stainless steel 316L components Variable Fused Deposition Modelling – analysis of benefits, concept design and tool path generation. Innovative features in implants through Beam Melting – a new approach for Additiven Manufacturing of endoprostheses Investigating the influence of build parameters on the mechanical properties of FDM parts Porosity as a key to increase material properties of laser sintered parts Software tools for rapid Prototype as Design Direct Manufacturing Design Rules A priori process parameter adjustment for SLM process optimization Surface roughness analysis in Selective Laser Melting AsTeRICS – a rapid prototyping platform for Assistive Technologies Comparison of five rapid prototype techniques (SLS/FDM/DLP/3DP/Polyjet) Droplet impact dynamics in ink-jet manufacturing Rapid Prototyping techniques for individualized medical prosthesis manufacturing Towards surface topography: Quantification of Selective Laser Melting (SLM) built parts An Additive Manufacturing method based on xerography Preliminary investigation on cellular support structures using SLM process Microchannels fabrication in Direct Metal Laser Sintering (DMLS) Knowledge based process planning and design for Additive Manufacturing (KARMA) A comparison of laser additive manufacturing using gas and plasma-atomized Ti-6Al-4V powders Thermoplastic filament extruder head for desktop Additive Manufacturing machines Manufacturing of defined porous metal structures using the beam melting technology 7. Virtual Environments and Simulation An ontology-based automotive troubleshooting configuration system development A tactile display for texture perception in virtual environments Virtual Reality technology as a support to the maintenance activity of buildings Some studies on dislocation density based finite element modeling of Ultrasonic Consolidation Virtua

Paulo Bártolo is Professor of Advanced Manufacturing Processes at the Polytechnic Institute of Leiria (IPL), Director of the Centre for Rapid and Sustainable Product Development of IPL and President of the Scientific Council of the Institute for Post-graduation Studies and Research of IPL. Paulo Bártolo is Editor-in-Chief of the Journal Virtual & Physical Prototyping, published by Taylor & Francis (ISSN 1745-2759)