Reverse engineering (RE) is a process that endeavors the functionality, fabrication, or design of a particular object to mimic/modify the same. Usually, reverse engineering involves three steps: system understanding, design understanding, and analysis. The first step consists of understanding the working principle of an object/system. In this, questions such as how the system works and why the particular mechanism/process is utilized for the system’s proper functioning are answered. In the second step, the design of the object/system is explored. This step also explores the mechanism design, material selection, and optimal working conditions. In the third step, system analysis towards the system working and design is done. The system is analyzed at this stage concerning its working principle, design, material selection, and optimal working conditions.

Forward engineering (FE) is a process in which the system/object is developed/produced as per the desired sets of requirements. Like RE, forward engineering has three steps: analysis, design, and implementation. In the first step, analysis is done as the need of the applications. The second step involves designing and simulating the system/object as per the working conditions and environment. The third step consists of the fabrication, testing, and final application of the system/object as per the given input parameters.

At BMTE, we implement both reverse engineering and forward engineering approaches. Usually, legally sourced CT/MRI images, µCT, 3D scan images, etc., are utilized to develop the 3D design of an object called the defect design. This step uses image processing software such as Simpleware, mimics, etc., to create the defect model. Based on defect design, geometrical analysis related to shape, size, etc., loading conditions such as load bearing, non-load bearing, or load sharing, and host materials such as soft tissue, hard tissue, etc., are explored. Further, the system is analyzed with an understanding of the defect model, related loading conditions, and host material properties. Till this step reverse engineering approach is utilized. Once sufficient knowledge of the system/object is achieved, the forward engineering (FE) approach emerges. This knowledge is used to develop patient-specific systems/objects in the FE. This step involves utilizing software such as mimics, Simpleware, Solidworks, etc. The designed objects/systems undergo simulations per the loading conditions and the host material properties with the help of FEM tools such as Ansys, Comsol, etc. The best design is selected for the fabrication. The fabricated systems/objects are further tested experimentally in the last step. The experiments involve fabrication optimization, mechanical validation such as destructive and non-destructive testing, and biological validations such as in-vivo, in vitro testing, immunological responses, anti-bacterial and anti-fungal testing, biocompatibility, etc., as per the ISO standards.

BMTE aims to develop novel products for the healthcare industry; therefore, most of the work is focused on fabrication and its experimental validation. Fabrication methods involve electrospinning for medical textiles, Green machine for metal and ceramics, near net shaping, VPP, 3D and 4D printing, casting and conventional machining processes, etc.