This paper discusses theuddesign and development of a prototype of a knee surgery cutting jig, the jigudholder, and the jig injection mold by Rapid Prototyping (RP). The aim of thisudstudy is to design a jig and a jig holder that allow surgeons to correctly,udprecisely, and consistently perform knee replacement surgery. The designudconcept for the surgery jig and jig holder was selected using the Pugh methodudwith medical-grade 316L stainless steel for material fabrication. A rapidudprototype model was built directly from its CAD model in stereo lithographyud(STL) format by using the Fused Deposition Method (FDM). MasterCAM and Moldflowudsimulation were performed to generated G-codes and a possibility of jigudfabrication using Metal Injection Molding (MIM), respectively. The Moldflowudresult provided an enhanced interpretation of the injection mold design. Audconceptual mold design was again developed by the FDM. The prototype of theudcutting jig and its holder underwent a machining process. The prototype wasudthen tested on dummy bones to determine the functional performance andudefficiency of the said prototype. Results indicated an increase in cuttingudaccuracy and cutting time compared with computer-assisted total knee surgeryudwithout the jig system.
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