Optimising the design workflow: From material selection to simulation and sustainability

Optimising the design workflow: from material selection to simulation and sustainability

In a previous paper, we proposed a framework to support engineering design by linking rational materials selection with simulation to optimise the design outcomes. The study was in two parts:

First, the selection of the most appropriate materials candidates for a total hip joint replacement, narrowed down from a domain of hundreds to just four. This selection process was carried out using Ansys Granta Selector software which contains advanced bio-engineering materials databases. Second: using the FEA tool Ansys Discovery, a simulation was run on the hip implant model, subjecting it to multiple structural forces similar to the stresses that a hip implant would face in-situ. The simulation was run with each of the material candidates as the assigned material for the implant to find the geometric design and material combination that would provide a lightweight solution with a suitable safety factor.

Along with other fields, there is a strong need and desire in the bioengineering field to understand and mitigate the environmental impacts of biomedical devices. In recognition of this, we have also carried out a sustainability assessment of the four materials candidates and compared them using the data in Granta Selector and the Eco-Audit tool. The comparison looks at the CO₂ footprint, embodied energy, and water usage associated with the primary production of the materials as well as energy and CO₂ emissions and end-of-life scenarios connected with manufacturing hip implants.