Research data supporting the thesis Non-assembly Additive Manufacturing of Medical Devices

In the medical field, non-assembly designs enable the creation of increasingly complex devices that can facilitate a wide range of complex operations. In conventional medical device manufacturing, intricate components are typically produced separately and then assembled, a process that introduces complexities, costs, and potential points of failure. Non-assembly additive manufacturing addresses these challenges by allowing the creation of complex medical structures, such as surgical instruments, prosthetics, and patient-specific implants, in a seamless and continuous manner. For the production of complex medical devices with miniature- and micro-sized components, for which conventional assembly processes can be long and time-consuming, non-assembly manufacturing can shorten the total manufacturing time, reduce costs, and eliminate the need for specialized knowledge and tools for the assembly and fine-tuning of the device. This efficiency is particularly crucial in the medical field, where timely access to customized and precise solutions can significantly impact patient outcomes. Non-assembly additive manufacturing also has the potential to drive innovation in medical device design. Designers and engineers can explore new possibilities, pushing the boundaries of what is achievable in terms of functionality, customization, and patient-specific adaptations. Therefore, the main purpose of the research described in this thesis, is to explore the possible contributions of non-assembly additive manufacturing to the production of complex medical devices.

在医学领域，无装配设计能够支持开发日益复杂的医疗器械，以辅助完成各类复杂临床操作。在传统医疗器械制造流程中，精密复杂的组件通常先分别生产，再进行组装——这一工艺会额外增加流程复杂度、提升制造成本，还会引入潜在的失效风险点。无装配增材制造（non-assembly additive manufacturing）可通过无缝连续的方式，直接制造手术器械、假肢、患者定制植入物等复杂医用结构，从而解决上述痛点。针对搭载微型及超小型组件的复杂医疗器械生产场景，传统装配流程往往耗时冗长，而无装配制造可缩短整体制造周期、降低生产成本，同时无需借助专业知识与工具完成设备组装与微调。这类效率优势在医学领域尤为关键——及时获取定制化且精准的医疗解决方案，可对患者预后效果产生显著影响。此外，无装配增材制造还有望推动医疗器械设计领域的创新。设计师与工程师可探索全新的设计可能性，突破现有功能、定制化程度以及患者适配性的实现边界。因此，本论文所述研究的核心目标，便是探究无装配增材制造在复杂医疗器械生产中的潜在应用价值。