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.

在医疗领域，无组装设计（non-assembly designs）可助力构建愈发复杂的医疗器械，以适配各类复杂手术操作。在传统医疗器械制造流程中，精密组件通常需先单独生产，再进行组装，该过程会引入额外复杂度、增加制造成本，同时产生潜在的失效风险点。无组装增材制造（non-assembly additive manufacturing）可有效解决上述难题：其可通过无缝连续的制造方式，直接制造诸如手术器械、假体以及患者特异性植入物等复杂医疗结构。针对带有微型乃至微小型组件的复杂医疗器械而言，传统组装流程往往耗时冗长，而无组装增材制造可缩短总制造周期、降低生产成本，且无需借助专业知识与专用工具完成设备的组装与微调。这种效率优势在医疗领域尤为关键，因为及时获取定制化且高精度的解决方案，可显著改善患者预后。此外，无组装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技术可能，突破功能、定制化以及患者适配层面的技术边界。因此，本论文所述研究的核心目的，即探究无组装增材制造在复杂医疗器械生产中的潜在贡献。