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Advanced Manufacturing Techniques for Implantable Blood Pumps / RHODRI REES

Swansea University Author: RHODRI REES

  • E-Thesis under embargo until: 12th December 2029

DOI (Published version): 10.23889/SUThesis.68980

Abstract

Left Ventricular Assist Devices (LVAD) have been developed to provide an alternative to heart transplant surgery.The manufacture of these devices by traditional routes is expensive, time consuming and labour intensive due to the complexity and the level of precision required of each component. Despi...

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Published: Swansea University, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Lavery, N. P.; Rees, A.; and Probert, D.
URI: https://cronfa.swan.ac.uk/Record/cronfa68980
first_indexed 2025-02-27T14:10:33Z
last_indexed 2025-02-28T05:34:41Z
id cronfa68980
recordtype RisThesis
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spelling 2025-02-27T14:15:26.1155467 v2 68980 2025-02-27 Advanced Manufacturing Techniques for Implantable Blood Pumps c979fef340d3336ea301c2f63efb29a3 RHODRI REES RHODRI REES true false 2025-02-27 Left Ventricular Assist Devices (LVAD) have been developed to provide an alternative to heart transplant surgery.The manufacture of these devices by traditional routes is expensive, time consuming and labour intensive due to the complexity and the level of precision required of each component. Despite significant developments in LVAD functionality in recent decades, manufacturability remains an issue, particularly as functionality is directly influenced by component geometries. Subsequently, the manufacturability of current LVAD components exceed traditional manufacturing process capabilities.This thesis explores the application of Laser Powder Bed Fusion (L-PBF), an advanced manufacturing technique which have been identified as a potentially feasible alternative to subtractive manufacturing, due to its ability to rapidly produce complex shaped geometries. L-PBF technology also benefits from the ability to process Ti6Al4V, a biocompatible material used for the majority of the components of an LVAD.Thermally induced residual stresses can lead to geometric inaccuracy within L-PBF made components. Part geometry and size can influence the amount of geometric displacement caused by L-PBF process-induced residual stress. Geometric shape retention is critical for an LVAD application due to exacting tolerances and precision fit between components. An analysis of various L-PBF made Ti6Al4V geometries was to prove that part geometry and size is a key driver of stress-induced geometric displacement. The position of a part on the build substrate has minimal effect on the amount of displacement, introducing the ability to position components without risk of high scrap rates.An investigation of a novel diffusion bonding process using Hot Isostatic Pressing equipment to combine joining and porosity reduction of L-PBF components is shown to be successful in principle. However, the process was unsuitable for medical device manufacture due to poor process control, poor shape retention and process repeatability. This method is better suited for solid-to-powder bonding. E-Thesis Swansea University, Wales, UK Additive manufacturing, laser powder bed fusion, Ti6Al4V, left ventricular assist device, residual stress, geometric displacement, hot isostatic pressing, diffusion bonding. 12 12 2024 2024-12-12 10.23889/SUThesis.68980 A selection of content is redacted or is partially redacted from this thesis to protect sensitive and personal information. COLLEGE NANME COLLEGE CODE Swansea University Lavery, N. P.; Rees, A.; and Probert, D. Doctoral EngD M2A, Calon Cardio-Technology Ltd M2A, Calon Cardio-Technology Ltd 2025-02-27T14:15:26.1155467 2025-02-27T14:05:13.0262644 Faculty of Science and Engineering School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering RHODRI REES 1 Under embargo Under embargo 2025-02-27T14:09:30.9112056 Output 11277877 application/pdf E-Thesis true 2029-12-12T00:00:00.0000000 Copyright: The Author, Rhodri Gwyn Rees, 2024 true eng
title Advanced Manufacturing Techniques for Implantable Blood Pumps
spellingShingle Advanced Manufacturing Techniques for Implantable Blood Pumps
RHODRI REES
title_short Advanced Manufacturing Techniques for Implantable Blood Pumps
title_full Advanced Manufacturing Techniques for Implantable Blood Pumps
title_fullStr Advanced Manufacturing Techniques for Implantable Blood Pumps
title_full_unstemmed Advanced Manufacturing Techniques for Implantable Blood Pumps
title_sort Advanced Manufacturing Techniques for Implantable Blood Pumps
author_id_str_mv c979fef340d3336ea301c2f63efb29a3
author_id_fullname_str_mv c979fef340d3336ea301c2f63efb29a3_***_RHODRI REES
author RHODRI REES
author2 RHODRI REES
format E-Thesis
publishDate 2024
institution Swansea University
doi_str_mv 10.23889/SUThesis.68980
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering
document_store_str 0
active_str 0
description Left Ventricular Assist Devices (LVAD) have been developed to provide an alternative to heart transplant surgery.The manufacture of these devices by traditional routes is expensive, time consuming and labour intensive due to the complexity and the level of precision required of each component. Despite significant developments in LVAD functionality in recent decades, manufacturability remains an issue, particularly as functionality is directly influenced by component geometries. Subsequently, the manufacturability of current LVAD components exceed traditional manufacturing process capabilities.This thesis explores the application of Laser Powder Bed Fusion (L-PBF), an advanced manufacturing technique which have been identified as a potentially feasible alternative to subtractive manufacturing, due to its ability to rapidly produce complex shaped geometries. L-PBF technology also benefits from the ability to process Ti6Al4V, a biocompatible material used for the majority of the components of an LVAD.Thermally induced residual stresses can lead to geometric inaccuracy within L-PBF made components. Part geometry and size can influence the amount of geometric displacement caused by L-PBF process-induced residual stress. Geometric shape retention is critical for an LVAD application due to exacting tolerances and precision fit between components. An analysis of various L-PBF made Ti6Al4V geometries was to prove that part geometry and size is a key driver of stress-induced geometric displacement. The position of a part on the build substrate has minimal effect on the amount of displacement, introducing the ability to position components without risk of high scrap rates.An investigation of a novel diffusion bonding process using Hot Isostatic Pressing equipment to combine joining and porosity reduction of L-PBF components is shown to be successful in principle. However, the process was unsuitable for medical device manufacture due to poor process control, poor shape retention and process repeatability. This method is better suited for solid-to-powder bonding.
published_date 2024-12-12T05:23:25Z
_version_ 1851550550631383040
score 11.089656

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