For sinus grafting, different methods and materials are available. One possible shortcoming of particulate bone grafts is either overfilling or augmenting the planned implant area insufficiently. To overcome this risk and to determine the implant position prior augmentation, we present an approach using three-dimensional printed scaffolds. A patient with a remaining anterior dentition and bilateral severely atrophied posterior maxilla was seeking oral rehabilitation. The cone beam computed tomography (CBCT) showed residual bone heights between one and two millimeters. Following the three-dimensional reconstruction of the CBCT data, the positions of the implants were determined in areas 16 and 26. Three-dimensional scaffolds adapted to the topography of the sinus were virtually designed and printed using a calcium phosphate cement paste. Bilateral sinus floor augmentation applying the printed scaffolds with an interconnecting porosity followed. After nine months, a satisfying integration of the scaffolds was obvious. At the re-entry, vital bone with sufficient blood supply was found. One implant could be placed in positions 16 and 26, respectively. After five months, the implants could be uncovered and were provided with a temporary denture. The application of three-dimensionally printed scaffolds from calcium phosphate cement paste seems to be a promising technique to graft the severely atrophied posterior maxilla for the placement of dental implants.

This work aims to evaluate the current state of research on the use of artificial intelligence, deep learning, digitalization, and Data Mining in product development, mainly in the mechanical and mechatronic domain. These methods, collectively referred to as “digital engineering”, have the potential to disrupt the way products are developed and improve the efficiency of the product development process. However, their integration into current product development processes is not yet widespread. This work presents a novel consolidated view of the current state of research on digital engineering in product development by a literature review. This includes discussing the methods of digital engineering, introducing a product development process, and presenting results classified by their individual area of application. The work concludes with an evaluation of the literature analysis results and a discussion of future research potentials.

Geometric deviation associated with the assembly of sheet metal is a general concern for manufacturers. The typical assembly step involves a sequence of events that exert forces on the parts to enforce them to the nominal condition and to connect the parts together. The simulation and optimization of the assembly steps often neglect the sequence of operations due to the problem and computation complexity. This paper investigates the influence of the clamping sequence in the body-in-white (BIW) manufacturing process on the geometrical quality of the assembly. An approach for modeling clamping sequences for non-rigid variation simulation is introduced in a digital twin context, taking the part deviation into consideration. An optimization method is proposed to achieve minimum geometric deviation after clamping the parts and welding them together. The method is successfully applied on two reference assemblies, and the results show that the sequence of clamping can impact the total geometric deviation up to 31%. Combining clamping and welding sequence optimization can enhance the quality improvement to 77% after releasing the assembly from the fixture and springback.

In the laser powder bed fusion processes for metal additive manufacturing, a support structure is needed to fix the part to the base plate and to support overhanging regions. Currently the importance of support structure for a successful build process is often underestimated and some effects are not yet well understood. Therefore, this study investigates the fracture behavior and mechanical properties of thin additive manufactured struts using the titanium alloy Ti-6Al-4V and specific machine parameters for support structures. Tensile tests were performed for different strut diameters and the fracture surfaces were analyzed using a laser microscope and a scanning electron microscope. Additionally, the porosity was examined with micro-CT scans. The results were compared with a different set of parameters used for solid parts. The experiments revealed that struts produced with support parameters had no significantly lower tensile strength than the comparative parts. Despite that, some porosity and around two percent of defects on the fracture surface for parts using the solid parameter set have been found. Parts with support parameters show no porosity, even though the energy density is around 30% lower compared to the solid parameter set.