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Nieuwe generatie van lichtgewicht mobiliteitsproducten en externe protheses

Nieuwe generatie van lichtgewicht mobiliteitsproducten en externe protheses. Iedere gram telt … Geert Smits, Mifa Aluminium BV, Aalberts Industries NV. The Dutch population numbers 16.7 million inhabitants today. 4,7% (± 800,000 people) of Dutch population need aids to enhance mobility

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Nieuwe generatie van lichtgewicht mobiliteitsproducten en externe protheses

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  1. Nieuwe generatie van lichtgewicht mobiliteitsproducten en externe protheses Iedere gram telt… Geert Smits, MifaAluminium BV, Aalberts Industries NV

  2. The Dutch population numbers 16.7 million inhabitants today 4,7% (± 800,000 people) of Dutch population need aids to enhance mobility Cain Crutch Walking frame Wheelchair 5,4% (± 900,000 people) of Dutch population use anatomic aids Orthopedic shoes Orthesis Prosthesis Data from CBS

  3. Like everyone else Stay active Be independent Have a social life Have a professional career Participate in sports Mobility and anatomic aids • Designed according to their individual needs • Shape • Size

  4. …But everyone wants lighter aids Energy efficient Easier to lift / push Competitive advantage

  5. And stiffer. And more comfortable. More efficient transfer of muscle power Better absorbance of shocks

  6. Translation of user requirements into the right material Light and strong - Specific Strength Material selection by the Ashby approach

  7. Translation of user requirements into the right material Light and strong - Specific Strength 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Material selection by the Ashby approach

  8. Translation of user requirements into the right material Light and strong - Specific Strength 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Light and stiff - Specific Stiffness 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Material selection by the Ashby approach

  9. Translation of user requirements into the right material Light and strong - Specific Strength 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Light and stiff - Specific Stiffness 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Shock absorbent - Specific Damping Capacity 1. Magnesium Alloys 2. Steels 3. Aluminium Alloys 4. Titanium Alloys Material selection by the Ashby approach

  10. Pros and cons of Magnesium - + • 40% lighter than Aluminium • 250% lighter than Titanium • 400% lighter than Steel • 30% better absorption of vibrations than Aluminium • Low deformability at room temperature • Low corrosion resistance • No readily available technology for manufacturing Magnesium parts

  11. Total Performance Approach Extrusion Bending Machining Finished product Welding and assembly Coating

  12. Challenges: Extrusion Optimization of die design Optimization of billet homogenizing treatments Optimization of extrusion temperature and speed Determination of extrudate strength Challenges: bending • Determination of minimum relative bending radius • Optimization of bending speed • Determination of spring-back • Optimization of bending temperature

  13. Bending at room temperature, speed 1 rpm

  14. Bending at 150°C, speed 1 rpm

  15. Challenges: Machining Optimization of feed rate Optimization of cutting speed Optimization of depth of cut Challenges: Coating • Optimization of pretreatments • Optimization of process parameters • Optimization of lacquering step • Wear resistance of coating • Corrosion resistance of coating

  16. Challenges: Welding and assembly Optimization of pre-treatments Optimization of filler feeding Optimization of alternating current Determination of joint strength Phase II: Manufacturing and biomechanical testing of prototypes • Starts summer 2012 • Selection of prototypes • Design of prototypes • Manufacturing of prototypes • Biomechanical testing of prototypes

  17. Phase II: Manufacturing and biomechanical testing of prototypes • Novel ultra-light wheelchair for tennis-star Sharon Walraven Sharon Walraven Silver medalist – Olympic Games Sydney 2000 (Ladies single) Gold medalist – Olympic Games Beijing 2008 (Ladies double)

  18. Future spin-offs after completion of the project Light-weight magnesium coated profiles and parts for High end sport bikes Automobiles Airplanes Portable electronics

  19. The members of the consortium would like to thank …..

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