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Surface roughness optimisation in FFF tibial insert patterns for silicone mould.

Raman Sharma1,2, Narendra Kumar1,3, Rajeev Trehan1

  • 1Department of Industrial and Production Engineering, Dr B. R Ambedkar National Institute of Technology, Jalandhar, Punjab, India.

Proceedings of the Institution of Mechanical Engineers. Part H, Journal of Engineering in Medicine
|May 22, 2026
PubMed
Summary

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This summary is machine-generated.

This study developed patient-specific knee implants using rapid tooling and 3D printing. Chemical vapour smoothing significantly improved the surface finish of 3D-printed patterns for silicone molds, enhancing implant precision.

Area of Science:

  • Biomaterials Engineering
  • Medical Device Manufacturing
  • Additive Manufacturing

Background:

  • Standardized knee implants limit precise anatomical fit and optimal gap filling.
  • Patient-specific implants offer improved alignment and function over traditional components.

Purpose of the Study:

  • To develop silicone molds for patient-specific tibial inserts using an indirect rapid tooling process.
  • To evaluate post-processing techniques for improving the surface finish of 3D-printed patterns for mold fabrication.

Main Methods:

  • Generated patient-specific total knee replacement (TKR) components from CT data.
  • Fabricated tibial insert patterns using Fused Filament Fabrication (FFF) with PLA.
  • Compared chemical immersion and chemical vapour smoothing for surface finish improvement.
Keywords:
3D scanadditive manufacturingknee replacementpatternrapid toolingsurface optimisationtibial insert

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  • Assessed surface quality using optical microscopy and 3D surface plots.
  • Main Results:

    • Chemical vapour smoothing improved pattern surface finish by approximately 80%.
    • Vapour smoothing uniformly modified the surface while maintaining geometric conformity.
    • FFF-fabricated molds with smoothed patterns exhibited reduced roughness (Ra 26.87 µm, Rq 33.58 µm) and improved surface morphology.

    Conclusions:

    • Chemical vapour smoothing is an effective post-processing technique for FFF-fabricated patterns.
    • This method enables the production of high-quality silicone molds for patient-specific tibial inserts.
    • The developed process facilitates the casting of epoxy-based composite biomaterials for custom knee implants.