Topology Optimisation of Lattice Structure Additive Manufactured Knee Implants

A Master's project to create a simulation that would optimise the volume fraction distribution of a lattice structure knee implant design, such that bone remodelling capability was maximised subject to the strength requirements of in-knee loading conditions being met. Three methods were explored: 'non-penalising stiffness-maximising topology optimisation'; 'looped stress limiting process'; 'non-penalising stress-constrained topology optimisation'. Designs were achieved from the first and second methods. The looped process gave different designs subject to initial conditions and iteration numbers. The designs were compared to a 'control' design with perfect bone remodelling capability but no strength consideration. The failure load of the 'control' design was ~600 N. The failure loads of the designs achieved from the simulations were much better, at 800 - 1000 N. The best design was 'stress limited control' - a single iteration of the looped process upon the 'control' design. The percentage of implant elements predicted to be at risk of in-knee failure fell by ~44.9% upon the 'control' design with only a 12% average deviation from ideal-remodelling modulus targets.

Additive manufactured implant designs
Additive manufactured implant designs

press to zoom
Volume fraction distribution visualisation of 'control' design
Volume fraction distribution visualisation of 'control' design

press to zoom
Stress and failure distribution visualisation of 'stress limited control' design
Stress and failure distribution visualisation of 'stress limited control' design

press to zoom
Additive manufactured implant designs
Additive manufactured implant designs

press to zoom
1/5

press to zoom

press to zoom
1/1

Nanofuels for the Control of Engine Emissions

An extensive literature review project to report the current state of research into the use of nanofuels to improve local and global scale combustion engine behaviour, and evaluation of practicalities of their use.

Image Source: Gan Y, Qiao L. Radiation-enhanced evaporation of ethanol fuel containing suspended metal nanoparticles

Symbioturner Section View
Symbioturner Section View

press to zoom
Symbioturner Side View
Symbioturner Side View

press to zoom
Symbioturner Section View
Symbioturner Section View

press to zoom
1/2

'The Symbioturner'

A group project to design an electronic hand-held key-turner for arthritic individuals. Less than 200g, can fit in a pocket and turns an average lock in two seconds.

Miniature Motor Car

A group project to design and manufacture a miniature motor car to be tested in a race, tug-of-war and 1000N loading test. The four wheel drive driveshaft design allowed for strong torque performance with minimal compromise on weight and speed. The car was undefeated in the tug-of-war and came 5th out of 28 entries in the race.

Motor Car Design
Motor Car Design

press to zoom
Motor Car Design
Motor Car Design

press to zoom
Manufactured Motor Car
Manufactured Motor Car

press to zoom
Motor Car Design
Motor Car Design

press to zoom
1/5

Chassis and Steering System of a High Efficiency Electric Vehicle

A group project to design, manufacture and test the chassis and steering system of Imperial's entry to Shell Eco-Marathon, an international fuel efficiency competition. The use of carbon fibre allowed for a 23% weight saving upon the previous generation vehicle.

Chassis Design
Chassis Design

press to zoom
Manufactured Chassis
Manufactured Chassis

press to zoom
Manufactured Chassis
Manufactured Chassis

press to zoom
Chassis Design
Chassis Design

press to zoom
1/3

Chassis and Steering System of a High Efficiency Electric Vehicle

A group project to design, manufacture and test the chassis and steering system of Imperial's entry to Shell Eco-Marathon, an international fuel efficiency competition. The use of carbon fibre allowed for a 23% weight saving upon the previous generation vehicle.

View Report

press to zoom

press to zoom

press to zoom

press to zoom
1/3

Uniwheel Transporter Drive Train

An individual project to design the drive train to a uniwheel transporter within prescribed space constraints.