Open Access

In this study, we tested the function of a replica of the over 500-year-old original of the famous Franconian Imperial Knight Götz von Berlichingen’s first “iron hand”, which we reconstructed by computer-aided design (CAD) and recently printed using a multi-material 3D printer. In different everyday tasks, the artificial hand prosthesis proved to be remarkably helpful. Thus, the hand could hold a wine glass, some grapes, or a smartphone. With a suitable pencil, even writing was possible without any problem. Although for all these functions the healthy other hand was necessary to assist at the beginning, the artificial hand is an astonishing mechanical aid with many possibilities. Therefore, in certain cases, the non-invasive approach of a passive mechanical hand replacement, which is an individual, quick and cheap solution due to modern 3D printing, may always be worth considering also for today’s requirements.

Knight Götz von Berlichingen (1480–1562) lost his right hand distal to the wrist due to a cannon ball splinter injury in 1504 in the Landshut War of Succession at the age of 24. Early on, Götz commissioned a gunsmith to build the first “Iron Hand,” in which the artificial thumb and two finger blocks could be moved in their basic joints by a spring mechanism and released by a push button. Some years later, probably around 1530, a second “Iron Hand” was built, in which the fingers could be moved passively in all joints. In this review, the 3D computer-aided design (CAD) reconstructions and 3D multi-material polymer replica printings of the first “Iron hand“, which were developed in the last few years at Offenburg University, are presented. Even by today’s standards, the first “Iron Hand”—as could be shown in the replicas—demonstrates sophisticated mechanics and well thought-out functionality and still offers inspiration and food for discussion when it comes to the question of an artificial prosthetic replacement for a hand. It is also outlined how some of the ideas of this mechanical passive prosthesis can be translated into a modern motorized active prosthetic hand by using simple, commercially available electronic components.

The visualization of heart rhythm disturbance and atrial fibrillation therapy allows the optimization of new cardiac catheter ablations. With the simulation software CST (Computer Simulation Technology, Darmstadt) electromagnetic and thermal simulations can be carried out to analyze and optimize different heart rhythm disturbance and cardiac catheters for pulmonary vein isolation. Another form of visualization is provided by haptic, three-dimensional print models. These models can be produced using an additive manufacturing method, such as a 3d printer. The aim of the study was to produce a 3d print of the Offenburg heart rhythm model with a representation of an atrial fibrillation ablation procedure to improve the visualization of simulation of cardiac catheter ablation. The basis of 3d printing was the Offenburg heart rhythm model and the associated simulation of cryoablation of the pulmonary vein. The thermal simulation shows the pulmonary vein isolation of the left inferior pulmonary vein with the cryoballoon catheter Arctic Front Advance™ from Medtronic. After running through the simulation, the thermal propagation during the procedure was shown in the form of different colors. The three-dimensional print models were constructed on the base of the described simulation in a CAD program. Four different 3d printers are available for this purpose in a rapid prototyping laboratory at the University of Applied Science Offenburg. Two different printing processes were used and a final print model with additional representation of the esophagus and internal esophagus catheter was also prepared for printing. With the help of the thermal simulation results and the subsequent evaluation, it was possible to draw a conclusion about the propagation of the cold emanating from the catheter in the myocardium and the surrounding tissue. It was measured that just 3 mm from the balloon surface into the myocardium the temperature dropped to 25 °C. The simulation model was printed using two 3d printing methods. Both methods, as well as the different printing materials offer different advantages and disadvantages. All relevant parts, especially the balloon catheter and the conduction, are realistically represented. Only the thermal propagation in the form of different colors is not shown on this model. Three-dimensional heart rhythm models as well as virtual simulations allow very clear visualization of complex cardiac rhythm therapy and atrial fibrillation treatment methods. The printed models can be used for optimization and demonstration of cryoballoon catheter ablation in patients with atrial fibrillation.

In this paper, a crack opening stress equation for in-phase and out-of-phase thermomechanical fatigue (TMF) loading is proposed. The equation is derived from systematic calculations of the crack opening stress with a temperature dependent strip yield model for both plane stress and plane strain, different load ratios and different ratios of the temperature dependent yield stress in compression and tension. Using a load ratio scaled by the ratio of the yield stress in compression and tension, the equation accounts for the effect of the temperature dependent yield stress and the constraint on the crack opening stress. Based on the scaling relation established in this paper, Newman's crack opening stress equation for isothermal loading is enabled to predict the crack opening stress under TMF loading.

Hybrid systems, unifying printed electronics with silicon‐based technology, can be seen as a driving force for future sensor development. Especially interesting are sensing elements based on printed devices in combination with silicon‐based high‐performance electronics for data acquisition and communication. In this work, a hybrid system integrating a solution‐processed organic photodiode in a silicon‐based system environment, which enables flexible device measurement and application‐driven development, is presented. For performance evaluation of the integrated organic photodiode, the measurements are compared to a silicon‐based counterpart. Therefore, the steady state response of the hybrid system is presented. Promising application scenarios are described, where a solution‐processed organic photodiode is fully integrated in a silicon system.

High temperature components in internal combustion engines and exhaust systems must withstand severe mechanical and thermal cyclic loads throughout their lifetime. The combination of thermal transients and mechanical load cycling results in a complex evolution of damage, leading to thermomechanical fatigue (TMF) of the material. Analytical tools are increasingly employed by designers and engineers for component durability assessment well before any hardware testing. The DTMF model for TMF life prediction, which assumes that micro-crack growth is the dominant damage mechanism, is capable of providing reliable predictions for a wide range of high-temperature components and materials in internal combustion engines. Thus far, the DTMF model has employed a local approach where surface stresses, strains, and temperatures are used to compute damage for estimating the number of cycles for a small initial defect or micro-crack to reach a critical length. In the presence of significant gradients of stresses, strains, and temperatures, the use of surface field values could lead to very conservative estimates of TMF life when compared with reported lives from hardware testing. As an approximation of gradient effects, a non-local approach of the DTMF model is applied. This approach considers through-thickness fields where the micro-crack growth law is integrated through the thickness considering these variable fields. With the help of software tools, this method is automated and applied to components with complex geometries and fields. It is shown, for the TMF life prediction of a turbocharger housing, that the gradient correction using the non-local approach leads to more realistic life predictions and can distinguish between surface cracks that may arrest or propagate through the thickness and lead to component failure.

In rural low voltage grid networks, the use of battery in the households with a grid connected Photovoltaic (PV) system is a popular solution to shave the peak PV feed-in to the grid. For a single electricity price scenario, the existing forecast based control approaches together with a decision based control layer uses weather and load forecast data for the on–off schedule of the battery operation. These approaches do bring cost benefit from the battery usage. In this paper, the focus is to develop a Model Predictive Control (MPC) to maximize the use of the battery and shave the peaks in the PV feed-in and the load demand. The solution of the MPC allows to keep the PV feed-in and the grid consumption profile as low and as smooth as possible. The paper presents the mathematical formulation of the optimal control problem along with the cost benefit analysis . The MPC implementation scheme in the laboratory and experiment results have also been presented. The results show that the MPC is able to track the deviation in the weather forecast and operate the battery by solving the optimal control problem to handle this deviation.