INTRODUCTION: This work aims to pre-operatively manufacture custom-made low-cost implants and physical models (‘biomodels’) of fractured skulls. The pre-DOI: operative manufacturing of biomodels and implants allows physicians to study and plan surgery with a greater possibility of achieving the expected result. Customization contributes to both the esthetic and functional outcome of the implant because it considers the anatomy of each patient, while the low cost allows a greater number of people to potentially benefit. METHODS: From CT images of a fractured skull, a CAD model of the skull (biomodel) and a restorative implant were constructed digitally. The biomodel was then physically constructed with 3D Printing, and Incremental Sheet Forming (ISF) was used to manufacture the implant from a sheet of pure grade 2 titanium. Before cutting the implant’s final shape from a pre-formed sheet, heat treatment was performed to avoid deformations caused by residual stresses generated during the ISF process. RESULTS: A comparison of the dimensions of the implant and its respective CAD biomodel revealed geometric discrepancies that can affect both functional and aesthetic efficiency. Nevertheless, the final shape preserved symmetry between the right and left sides of the skull. Electron microscopy analysis did not indicate the presence of elements other than pure titanium. CONCLUSION: Dimensional variability can be decreased with changes in the manufacturing process (i.e., forming and cutting) and the heating ramp. Despite biomedical characteristics, there was no contamination of the implant by harmful chemical elements. 3D Printing was effective in making the biomodel, enabling pre-operative planning and improving physician-patient communication. Current results indicate that ISF is a process that can be used to obtain custom-made implants.

This paper aims to present an active learning model for the implementation of in-novative teaching-learning practices in Higher Education, based on Active Learn-ing Methodologies by highlighting especially, PBL – Problem Based Learning using Rapid Prototyping devices. In order to apply PBL’s methodology to the courses, an implementation model with four levels of implementation was devel-oped. Each level has four class attributes, which are the problem’s scope, student autonomy, teaching role and classroom space-time. The obtained results show that the students demonstrate higher levels of interest, participation, and involve-ment with classmates, motivation and content’s perennial assimilation. With the application of these methodologies, skills required by job market, such as team-work, relationship, collaboration, proactivity and entrepreneurship are also devel-oped.

The objective of this study was to characterize austenitic stainless steel 310 produced by Wire and Arc Additive Manufacturing (WAAM), addressing a gap in the literature regarding this alloy. Microstructural, chemical, and mechanical analyses were performed. Optical and electron microscopy revealed a predominantly columnar grain structure with characteristic tracks along the deposition direction. Point and mapping EDS analyses indicated a homogeneous distribution of iron, chromium, and nickel; however, point measurements suggested a possible underestimation of nickel, likely due to high relative error. Tensile tests demonstrated anisotropic mechanical behavior, with yield strength meeting standards at 45° and 90°, but lower at 0°. Ultimate tensile strength and elongation were below conventional requirements, with a maximum elongation of 15% at 90°. Additionally, the sample exhibited a total porosity of approximately 0.89%, which contributes to the reduction in mechanical properties, especially in the direction parallel to the deposition tracks. Overall, the WAAM-produced 310 stainless steel presented a microstructure similar to hot-rolled and annealed AISI 310 steel, but with distinctive features related to the additive process, such as mechanical anisotropy and microstructural directionality. These limitations highlight the need for process optimization to improve mechanical performance but reinforce the alloy’s structural potential in additive manufacturing.

Objective: To analyze the efficiency of a hybrid manufacturing process that combines arc and wire additive manufacturing (WAAM) with hot forging, using the UTP DUR 600 consumable, evaluating its effects in the microstructure and mechanical properties of pen type hammers. Theoretical Structure: Additive manufacturing (AM) allows for the rapid and precise creation of complex projects, making the WAAM technique a promising alternative for its ability to deposit large volumes of material. However, its lower surface precision can be compensated by subsequent processes, such as hot forging — a technique consolidated in the industry for improving the mechanical properties of two metals by means of plastic deformation at high temperatures. Method: Metal pieces are manufactured by WAAM with the UTP DUR 600 electrode arame, deposited layer by layer, and subsequently submeted into the forging by quente. Avaliaram-se alterações microestruturais, including the recrystallization dynamic, or refinement of grains, or alignment of the fibers of the material and the distribution of phases. The effects of temperature and deformation rates are also considered. The resistance to abrasive wear was validated with a non-flat base of the deposit path. Results and Discussion: The forging caused dynamic recrystallization and significant alterations in the microstructure of the UTP DUR 600 liga, including the refinement of grains and the realinhamento of the fibers of the material. These changes contribute to the increase in mechanical resistance and tenacity of parts. Abrasive wear resistance also presents advantages, associated with the planing of the deposition process and the forging conditions. Research Implications: The study demonstrates that the combination of WAAM with quente forging can overcome surface precision limitations of additive manufacturing, offering parts with better mechanical properties. A detailed analysis of the process variables contributes to the optimization of industrial parameters in applications that demand high wear resistance. Originality/Value: The research presents an innovative approach to integrating additive manufacturing by arame arc with hot forging, investigating its microstructural and mechanical effects in a high hardness league. This combination is still little explored in the literature, especially in the manufacturing of fine components, offering significant advances in the performance and durability of two components.