Shayan Darzi

Ph.D. candidate researches customized implants with DSIF innovation
Shayan Darzi works with ABB robot

Mechanical engineering Ph.D. candidate Shayan Darzi is researching new applications of the double-sided incremental forming (DSIF) machine at the Olson Center. Alongside his advisors, Shayan's research aims to utilize the DSIF process's flexibility to change the mechanical properties of sheet metal parts as they are being formed. By doing so, he seeks to create pieces with tailored mechanical properties that can be used in various applications, particularly in the medical field.

Shayan's research primarily aims to create patient-specific implants for individuals with fractures in their skulls or other body parts. Traditionally, implants are not customized to the specific patient, limiting their performance and healing time. Shayan's research aims to convert CT scan data into a CAD model. He then intends to use the CAD model and form the implant through the DSIF machine to produce a customized implant for each patient.

The key challenge lies in achieving higher strength in specific areas of the implant, such as the edges that will be mounted to the cranial bone, without changing the overall thickness of the part. Utilizing the DSIF machine is imperative as it offers flexibility in forming complex shapes and modifying the mechanical properties of the sheet metal during the forming process. Shayan plans to create implants tailored to each patient's anatomy and possess superior mechanical properties to enhance their performance in the patient's body.

Although Shayan and his advisors are still researching the ability to change the mechanical properties of these metals, this research is a fascinating step forward for the capabilities of metal sheet forming.

Written by Katelyn Clark '24