The femur is the longest and strongest bone in the human body. The tibia lies distal to the femur and medial to the fibula. The proximal end consists of medial and lateral condyles, an intercondylar area, and the tibial tuberosity that articulates with the medial and lateral condyles of the femur. Distally, the tibia articulates with the ankle. The distal and proximal ends of the tibia articulate with the fibula.
In addition, the shaft of the tibia and fibula are connected with an interosseous membrane to form a syndesmosis joint.
The fibula does not articulate with the femur or patella. Furthermore, the fibula is not directly involved in weight transmission. The patella is the largest sesamoid bone in the human body. This bone is flat, proximally curved, and distally tapered; however, the shape can vary.
The posterior patella articulates with the femur, but the apex sits proximal to the line of the knee joint. The tendon of the quadriceps femoris completely encompasses the patella.
The knee joint articulations are two condylar joints between the femur and the tibia as well as a joint between the patella and the femur. Although the fibula is closely related to the knee joint but it doesn't share in articulation.
However, the only forces the part undergoes is: two snug nut and bolts to secure the Knee T with an end plate and a high compressive strength is not required Figure 5. Figure 5: Knee T with tightened nut and bolt. The third concern was the importance of the maintaining a flat surface on the Knee T along the leg. If any hardware stuck out it would affect the alignment of the Knee T and thus the alignment of the finished product.
This was for multiple reasons: Firstly, ULTEM has the highest tensile and compressive strength of any FDM thermoplastic which made it the best choice to not crack under the tightened nut and bolt pressure.
To solve the problem of a maintaining a flat and level surface against the leg, new hardware was chosen to accommodate the application. A countersunk bolt provided a simple and effective solution for providing a flush surface Figure 6. Figure 6: Flush countersunk bolts. In doing so, they were able to eliminate internal components that were only required due to traditional manufacturing of the original parts. A simplified version of the component was able to be produced through the reverse engineering process.
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