ADDITIVE MANUFACTURING:
FUNDAMENTALS AND
APPLICATIONS
(ME3333E)
ASSIGNMENT
Design and Additive Manufacturing
Workflow of a Femoral Stem
Submitted by:
(GROUP 2)
Dheeraj M T (B230289ME)
Muhammed Hazem Rizvi (B230064ME)
Amal K (B230163ME)
Akhil Aravind (B230151ME)
Introduction
This work focuses on the design and additive manufacturing
preparation of a femoral stem component. The femoral stem is the
part of the hip implant. The femoral stem was modelled using solid
works software with appropriate dimensions to mimic the design of
the implant. The model was then converted into STL format, followed
by mesh inspection and validation.
Further, slicing was carried out using an FDM-based approach with
suitable process parameters. Different build orientations were
analysed, and an optimal orientation was selected based on factors
such as support requirement, printing time and structural design.
Finally, toolpath generation and G-code creation was done to simulate
the layer-by-layer fabrication process.
CAD Modelling
The femoral stem model was created using SolidWorks. The geometry was developed as a
representation of a typical femoral stem, focusing on ease of modelling and suitability for
additive manufacturing. The dimensions of the femoral stem can vary from person to person,
hence satisfactory dimensions were considered in design convenience.
The modelling started from a 2D sketch subsequently extruded to get the 3D model. Fillet
operations is done on the edges to ensure smooth edges and avoid stress concentration. A
cylindrical neck feature was added at the top of the stem using an additional extrusion. The
completed CAD model was verified visually to ensure proper geometry before proceeding to
the STL conversion stage.
CAD Model Screenshots:
STL Conversion and Mesh Analysis
The CAD model of the femoral stem was converted into
STL format using SolidWorks.
To check the effect of mesh resolution on surface quality
and file size, the model was exported using two different
resolution settings: coarse and fine. The export
parameters and corresponding mesh characteristics were
analysed.
In the coarse mesh, the model was generated with a
deviation tolerance of approximately 0.2009 mm and an
angular tolerance of 30°. A total of 1,368 triangular
elements with a file size of 68,484 bytes. The coarse
mesh provided a rough approximation of curved surfaces, with visible faceting.
In the fine mesh, the deviation tolerance was reduced to approximately 0.0774 mm and the
angular tolerance to 10°. This significantly increased the number of triangular elements to
5,128, with a corresponding file size of 256,484 bytes. The fine mesh resulted in a much
smoother surface representation, especially in curved regions of the model.
From the comparison, it was observed that increasing
mesh resolution improves geometric accuracy and
surface quality. The file size and computational
requirements will be increased. The fine mesh was
therefore selected for further processing.
The STL files were visually inspected to analyse the
mesh density and distribution of triangular facets before
proceeding to the next stage.
(coarse mesh) (fine mesh)(final)
Geometry Inspection and Repair
The generated STL file was inspected for geometric errors using the built-in diagnostic tools
available in SolidWorks. The inspection process focused on identifying common issues such
as gaps, non-manifold edges, and faulty faces that could affect the printability of the model.
The STL file was imported and analysed using the “Import Diagnostics” feature. The
geometry was checked for inconsistencies, and the automatic repair option was used where
necessary to correct any detected issues.
After the inspection and repair stage the geometry was free from errors and faulty faces. The
final model is analysed and was verified to ready to move to the next stage.
Slicing and Support Generation
The validated STL model was
imported into Ultimaker Cura for
slicing and preparation for additive
manufacturing. The slicing process
was carried out for a Fused
Deposition Modeling (FDM) using
Polylactic Acid (PLA).
The following values for each
parameter are considered:
• Layer height = 0.2 mm
• Infill density = 20%
• Infill pattern = Triangles
• Shell thickness = 1.2 mm
Support structures were enabled to accommodate
overhanging regions of the femoral stem,
particularly near the neck area. Tree-type supports
were selected, as they reduce material usage and are
easier to remove. The support placement was set to
“touching build plate” ensuring that supports are
generated only where necessary, minimizing contact between the support structures and the
body itself. Enabling build plate adhesion reduces the risk of wrapping and hence improve
print stability.
The model was then sliced to generate the layer-by-layer toolpath, and the preview was
analysed to verify support placement, infill structure, and overall printing.
Build Orientation Analysis
The build orientation of the femoral
stem was analysed by considering
two possible configurations: vertical
(upright) and horizontal (lying flat).
Each orientation was evaluated based
on factors such as support
requirement and print time.
In the vertical orientation, the model required minimal support
structures mainly near the neck region. The vertical alignment
is also followed in the manufacturing of the actual product. So
based on this it was concluded to have a better strength while
printing in the vertical direction rather than the horizontal
direction.
Even though the horizontal orientation is predicted to have
better print stability the requirement of large support structure
along the part increases the cost and the printing time. So it
was concluded it is better to have the vertical direction rather
than horizontal orientation.
Toolpath and G-code Generation
The final toolpath for the femoral stem model was generated using Ultimaker Cura after
completing the slicing process. The toolpath represents the sequence of movements followed
by the printer nozzle during the printing process. The model was visualized in preview mode
to analyse the layer-by-layer deposition.
Different visualization modes were used to analyse key printing parameters. The layer height
distribution was checked to evaluate uniform layer deposition, ensuring consistent build
quality. The speed distribution shows controlled variation in print speed across different
regions, optimizing both print quality. Additionally, the volumetric flow rate analysis showed
how material extrusion varies depending on geometry complexity, particularly in curved neck
sections.
The infill and outer wall toolpaths were observed, showing a good deposition pattern. The
internal infill pattern ensures material efficiency while maintaining structural strength
outside.
Finally, the G-code file was generated.
(the necessary supporting screenshots are followed)
Conclusion
This assignment have successfully demonstrated the complete workflow involved in additive
manufacturing, starting from CAD modelling to final G-code generation. A simplified
femoral stem was designed and prepared for fabrication using an FDM-based approach.
Each stage of the process such as STL conversion, mesh analysis, geometry validation,
slicing, and toolpath generation, was carried out. The effect of mesh resolution, build
orientation, and slicing parameters on the final outcome was clearly observed.