Based in Oxford, Meshworks specializes in creating custom orthopedic implants for joint repair surgery. Through laser powder bed fusion (LPBF), they produce intricate geometries that aim to improve the surgical procedure and patient outcomes and enhance osseointegration, expanding computational design and manufacturing possibilities.
The Challenge
Meshworks’ implants are tailored for anatomical regions (like foot, ankle, and wrist), and every patient requires a unique solution. Managing this level of mass customization is time-consuming and costly. Furthermore, the LPBF-based manufacturing process for titanium alloys introduces challenges, like the need for extensive support structures, which add material, time, and complexity to implant production. Reliable algorithms are crucial for ensuring consistency and reducing these bottlenecks.
Our Solution
At Object, we worked closely with Meshworks to simplify and refine their workflow. Our solution involved programming and R&D. We developed algorithmic tools to generate consistent implant geometry outputs, reducing the need for excessive support structures and helping balance implant requirements with production efficiency. A significant focus was also placed on optimizing the mesh topology for: structural strength, ensuring self-support through maximizing vertical elements, and controlled pore sizes to facilitate easy removal of support structures where necessary.
We aimed to make these tools as intuitive as possible, focusing on ease of use without compromising functionality. By integrating the solution into Rhino Grasshopper, we provided Meshworks with a streamlined, visually guided interface. To further support their goals, we designed custom components for analyzing geometry under their specific manufacturing constraints, allowing for a more efficient and accessible workflow.
The Outcome
With our solutions in place, Meshworks achieved:
- Simplified manufacturing with reduced reliance on complex support structures.
- Accelerated design workflows powered by adaptable, generative mesh tools.
- Enhanced usability, making advanced geometry tools accessible to their team.
This collaboration didn’t just improve processes—it made it easier for Meshworks to focus on what they do best: creating implants that help people heal.