Incremental Sheet Forming (ISF) is a new sheet metal forming process with several advances but still few knowledgement developed when polymeric materials are applied. Without considering material properties, ISF is used due to its flexibility, low cost and highly customized product production. Biomedical field is a growing up demanding production with special needs on customized product. For this reason ISF seems to be the ideal process for prosthesis production. There are several research works on ISF technology as production system for producing biocompatible devices with titanium sheet metal parts, while there is no work with polymeric materials published. There are two different types of ISF technologies in the literature so called Single Point ISF and Two Point TPIF. The goal in this project is to study and characterize the ISF process with two bicompatible materials such as (UHDPE and PMMA) by utilizing cranial prosthesis geometrical features. Methodology will be based on: a) Characterizing biocompatible material, b) SPIF experimental work with basic geometries, c) Simulation of basic geometries in SPIF process, d) Manufacturing alternatives analysis, e) Cranial prosthesis as case study. Each methodology step is related to specific goal of this project. This project involves experimental work and numerical simulation with basic geometries at first stage and real case study at the end. Both geometries will allow increasing knowledge in SPIF process. Expected results of this projects could be summarized as: a) obtaining a correct constitutive model for biocompatible polymer material, b) knowledge regarding the influence of SPIF process parameters on the final geometry variables as dimensional accuracy, roughness, etc. c) development of a numerical prediction methodology for the process studied on biocompatible polymer materials d) explore alternative materials such process variants (Two Point ISF) and the complementarity of SPIF with other polymer materials process and finally e) obtaining a biocompatible polymer prosthesis material by SPIF.
The improvement of each stage of the proposed methodology will provide the progress needed to meet ISF technology with biocompatible polymers in the medical-prosthetic sector.