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 Cain Crutch Walking frame Wheelchair 5,4% (± 900,000 people) of Dutch population use anatomic aids Orthopedic shoes Orthesis Prosthesis Data from CBS

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

…But everyone wants lighter aids Easier to lift / push Competitive advantageEnergy efficient

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

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

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

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

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

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 + -

Total Performance Approach ExtrusionMachiningBending Welding and assemblyFinished productCoating

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

Bending at room temperature, speed 1 rpm

Bending at 150°C, speed 1 rpm

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

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

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

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

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