Recent Advancements in the Bio-medical Implant Production using Additive Manufacturing – Comparison, Challenges and Future Scope Madhanagopal Manoharan, Bhavadharani Babu, Sindu Divakaran, Gobi Saravanan Kaliara, Perumal Sudalai, Rajendra Thilahar Chelladurai Biomedical and Pharmacology Journal, 2025 The usage of Additive Manufacturing (AM) by the healthcare industry to manufacture biomedical implants results in mass customized product at an affordable price. Prior to the advent of AM, these biomedical implants are fabricated using conventional manufacturing techniques such as casting, machining etc. These patient specific implants may aid the medical workers in the placement, inventory with increased customer satisfaction. There is a clear distinction between make or buy decision for these medical implants and systematic investigation is needed to procure these AM implants. In addition, these implants are designed and manufactured from the Digital Imaging and Communication in Medicine (DICOM) file from the respective patients. Polymer based Material Extrusion and Resin based Vat Photo polymerization are the commonly used AM techniques, which assist the health workers in validating the implant design. While the metal AM technique such as Powder Bed Fusion are used the widely employed method to fabricate the actual medical implants, which can be directly fit on the patient body. Most of the implants are used for dental applications using maxillofacial surgery and orthopaedic applications for bone joints. This paper briefs the impact of AM in the healthcare industry for mass customisation, strategies, methodologies and applications especially for implants. And some of the software tools used for the design, analysis and manufacturing of these implants are also discussed. Mass customisation and cost effectiveness are the major driving force for the use of medical implants. These patient specific medical implants with AM are useful for developing industries to overcome the expense associated with patient specific medical implants, which is usually fabricated using conventional manufacturing processes.
Mechanical and Sliding Wear Characterization of LM14 Aluminium Metal Matrix Hybrid Composites Perumal Sudalai, Madhanagopal Manoharan, Ajithram Arivendhan, Rajendra Thilahar C International Research Journal of Multidisciplinary Technovation, 2025 Generally, Aluminium alloys are used as the construction material for the engine pistons. This paper discusses the use of hybrid aluminum matrix composites to enhance the mechanical properties of the piston. The major components of the matrix are LM14, silicon carbide (SiC), boron carbide (B4C) and graphite (Gr). Addition of SiC improves the strength and thermal properties of the piston. Gr addition leads to better lubrication properties, which eventually reduce the wear rate of the piston. Tensile test, hardness test, wear rate, and thermal properties are analyzed in the fabricated samples. Thus, the novel hybrid composite material was proven to withstand high temperature applications, especially for pistons. Further, the durability of the piston can be enhanced with the introduction of these matrix components.
AFFORDABLE COLLABORATIVE ROBOT TECHNOLOGY FOR HUMAN-ROBOT COLLABORATION APPLICATIONS Madhanagopal Manoharan, Ranga Rakesh Ranganayakulu, Senthilkumaran Kumaraguru ASME International Mechanical Engineering Congress and Exposition Proceedings Imece, 2025 Industrial robots are increasingly used in a variety of industries and applications. Robot arms are classified according to their parameters, such as reachability, number of axes, payload capacity etc. In the age of Industry 4.0, Collaborative Robots (Cobots) play a crucial role in automating manufacturing systems, enhancing productivity, and ensuring safety. The key characteristic of CoBots is their ability to collaborate with humans, making them adept in context-aware and situation-aware applications. This study introduced an innovative approach that transforms an open-source, cost-effective industrial robot into a CoBot, which can be easily and quickly adopted in manufacturing. In Human-Robot collaboration, a pivotal task involves detecting humans within their workspace, accomplished through visual sensors. A neural network model is deployed to detect human presence using the deep learning-based Convolution Neural Network algorithm with the images captured from the workspace. This frugal sensor technology was developed, and the surface of the robot arm is covered with an indigenously developed, affordable capacitive touch sensor made of aluminium foil, which acts as a sensor to detect a human touch on the surface. Both human intrusion and human touch technology are used to stop the motion of the robot arm, thus enhancing safety in the robot workspace environment. This sort of human-robot collaboration using affordable technical solutions will be useful for robot control applications in the aerospace, defence and automobile industries, thereby improving productivity in the workplace.
FUTURE OF LIGHTWEIGHT DESIGN: ADVANCEMENTS IN LATTICE STRUCTURE THROUGH ADDITIVE MANUFACTURING AND SLS 3D PRINTING TECHNOLOGY Aruna Veerasamy, Kanimozhi Balakrishnan, Madhanagopal Manoharan ASME International Mechanical Engineering Congress and Exposition Proceedings Imece, 2025 In the manufacturing industries, there is a demand for lightweight, high performance, which may lead to the application of lattice structures as transformative solution in Additive Manufacturing (AM) or 3D printing. This is based on the inherent excellent strength weight ratios, better energy absorption capacity, and tailorable geometries for aerospace, automotive, and biomedical applications. The current research applies an experimental realization of optimized lattice models with the following materials: Nylon 12, Nylon 12 with glass fiber, Poly Propylene, and Nylon 12 with carbon fiber material. Selective Laser Sintering (SLS) type 3D printing technology is used for manufacturing products in this study. Lattice structure were designed and tested using tensile and compression tests. Materials were characterized by FESEM, XPS, Raman spectroscopy, and shore D hardness analysis after the SLS process. Meanwhile, CATIA 3D Experience software is used to design the ASTM and lattice model for this study. This work shows the potential of integrating advanced computational tools, innovative lattice concepts, and optimized AM processes to overcome challenges related to material limitations, scalability, and sustainability. These designs and materials are validated for their efficiency, durability and functionality to enhance performance. These findings are the key for the development of next generation lightweight components with enhanced performance and broader engineering applications.
A STUDY ON AFFORDABLE CRANIAL POLYMER IMPLANTS WITH POROUS STRUCTURES DEVELOPED USING MATERIAL EXTRUSION Bhavadharani B., Madhanagopal Manoharan, Gobi Saravanan K., Perumal Sudalai ASME International Mechanical Engineering Congress and Exposition Proceedings Imece, 2025 Head injuries are the most common cause of death and disability associated with road accidents, which account for 1.7 million people per year. The cranium in the skull encloses the brain and it is attached to head and neck muscles, which are protected by a combination of occipital, parietal, frontal, and temporal bones. These bone structures are further divided into various levels signified by scales such as macroscale, microscale and nanoscale. Replicating those bones and replacing them in the broken portion of the skull is a tedious process. However, a solution using Additive Manufacturing (AM) by printing customized implants for the damaged portion of the skull is possible. For this application, the 3D bio models are developed with the help of therapeutic imaging procedures such as Computed Tomography (CT) and Magnetic Resonance Imaging (MRI) techniques. These prosthetics replace skull fragments lost to surgery, trauma, or congenital defects. By imitating real bones, these bio-artificial implants provide support and tissue regeneration. The goal is to support patients undergoing extensive therapy and assist surgeons in effective cranial implant procedures. This study focuses on affordable polymer-based bio-implants made from Poly Lactic Acid (PLA), which plays a major role for possible replacement of metal AM implants for customized cranial implants. Growth and flexibility of the bone-tissue interaction need to be studied during the osseointegration stage. This work will be useful for applications such as developing biomedical and dental implants.
Strength characteristics of steel fiber reinforced concrete with sugarcane bagasse ash and wood ash Raghuram S, Madhanagopal Manoharan, Gayathri V, Rajendra Thilahar C Engineering Research Express, 2024 Fibre-reinforced concrete is an ancient technique that involves adding natural or synthetic materials to control deformations and cracking during service. Additionally, the use of agricultural waste materials like sugarcane bagasse ash (SBA), rice husk ash, wood ash (WA), and sawdust, as well as industrial by-products such as ground granulated blast furnace slag, fly ash, and copper slag, has been widely researched as substitutes for traditional binder materials. In line with these studies, an investigation was conducted to explore the surface profile and strength characteristics of steel-fibre reinforced concrete. Percentage Replacement of Steel Fiber (PRSF) by the concrete volume, along with the binder material, was partially replaced with WA and SBA. The concrete samples were cast for M20 grade, and the binder was replaced by 5% of SBA and partial replacement of WA by 5%, 10%, and 15% for cement. From the outcomes, the most desirable percentage recommended was 2% steel-fibre by volume of concrete, 5% replacement of SBA, and 10% replacement of WA by cement, which shows a reasonable amount of increase in the strength of concrete with a maximum of 28 curing days. Also, surface morphological studies of composites were studied using a Scanning Electron Microscope (SEM), by which the bonding property and performance of concrete show a considerable increase in the strength of the composites.
Prediction of wear volume and friction coefficients of SS304 alloy using grey taguchi-based response surface methodology Palanikumar Ponnuswamy, Madhanagopal Manoharan Materials Research Express, 2024 The present investigation is centered on examining the tribological characteristics within a pin-on-disk configuration resembling a cylinder on a flat contact surface. The pin, constructed from Stainless Steel 304 alloy, underwent sliding experiments under varying speeds (1, 2, and 3 m s−1) and normal loads (10, 15, and 20 N) across track diameters of 60 and 120 mm. The experiments aimed to mitigate wear and friction in movable components, thus conducted for up to 2000 s in the experimental setup without any lubrication. Observations of the coefficients of friction stabilization and wear rate were made by manipulating the input parameters to anticipate the failure range. Higher coefficients of friction and increased wear rates were noted at lower sliding speeds, with wear rates stabilizing at higher speeds. Interestingly, despite a higher coefficient of friction stabilization and wear rate at a 120 mm track diameter, wear decreased. Optical Microscopy studies were carried out to examine surface damage for all normal loads and sliding speeds using both 60 mm and 120 mm track diameters. Additionally, this study employs Grey Taguchi-based Response Surface Methodology (GT-RSM) to forecast and regulate wear and friction. The findings of this study have practical implications for industries such as automotive, aerospace, and others employing SS 304 alloys in their operational components.
Exploring the impact of computationally generated auxetic metamaterials in additive manufacturing: a systematic review of design, materials and applications JAN Madhanagopal Manoharan, Kaliaraj Gobi Saravanan, T. Sasipraba ... Archives of Civil and Mechanical Engineering 26 (88) , 2026 2026
A Study on Affordable Cranial Polymer Implants With Porous Structures Developed Using Material Extrusion PS Bhavadharani B., Madhanagopal Manoharan, Gobi Saravanan K. ASME 2025 International Mechanical Engineering Congress and Exposition … , 2025 2025
Affordable Collaborative Robot Technology for Human-Robot Collaboration Applications M Manoharan, RR Ranganayakulu, S Kumaraguru International Mechanical Engineering Congress and Exposition-India 89169 … , 2025 2025
Future of Lightweight Design: Advancements in Lattice Structure Through Additive Manufacturing and SLS 3D Printing Technology A Veerasamy, K Balakrishnan, M Manoharan International Mechanical Engineering Congress and Exposition-India 89138 … , 2025 2025
Recent Advancements in the Bio-medical Implant Production using Additive Manufacturing – Comparison, Challenges and Future Scope RTC Madhanagopal Manoharan, Bhavadharani Babu, Sindu Divakaran, Gobi ... Bio-medical and Pharmacology Journal 18 (3), 2083-2101 , 2025 2025
Mechanical and Sliding Wear Characterization of LM14 Aluminium Metal Matrix Hybrid Composites P Sudalai, M Manoharan, A Arivendhan, R Thilahar International Research Journal of Multidisciplinary Technovation 7 (1), 115-122 , 2025 2025
Strength characteristics of steel fiber reinforced concrete with sugarcane bagasse ash and wood ash S Raghuram, M Manoharan, V Gayathri, R Thilahar Engineering Research Express 6 (4), 045116 , 2024 2024 Citations: 3
Electromyography (EMG) Signal Acquisition for Exoskeleton Control: Enhancing Precision in Human-Machine Interaction R Thilahar C, ... 2024 Citations: 2
Prediction of wear volume and friction coefficients of SS304 alloy using grey taguchi-based response surface methodology P Ponnuswamy, M Manoharan Materials Research Express 11 (6), 066515 , 2024 2024 Citations: 2
A Study on the Use of Functionally Graded Lattice Structures for Optimizing the Design of Femoral Prosthesis M Manoharan, GS Kaliaraj, P Sudalai, S Preethi, S Varghese International Conference on Additive Manufacturing, 89-99 , 2024 2024 Citations: 1
Distortion Analysis of Dental Models Printed Using Material Jetting Technology M Manoharan, GS Kaliaraj, P Ponnusamy, A Veerasamy, S Kathiravan International Conference on Additive Manufacturing, 101-110 , 2024 2024
Investigation on environmentally polluted water hyacinth with banana fibre reinforced composite absorption properties A Ajithram, JT Winowlin Jappes, S Perumal, SD Kumar, M Manoharan Materials Science Forum 1112, 33-40 , 2024 2024 Citations: 1
Investigation on influence of die electric medium in electrical discharge machining of monel 400 alloy M Manoharan, S Perumal, A Ajithram, SD Kumar, J Ekanthamoorthy Applied Mechanics and Materials 919, 3-10 , 2024 2024 Citations: 3
Industry 4.0 and Advanced Manufacturing A Chakrabarti, S Suwas, M Arora Proceedings of, 1-4 , 2024 2024 Citations: 8
Experimental investigation of strength characteristics of concrete reinforcement with neem powders S Raghuram, M Manoharan, A Devanandhu Materials Today: Proceedings , 2023 2023 Citations: 3
Novel process planning approach for support-free additive manufacturing using multi-axis deposition systems M Manoharan, S Kumaraguru International Journal of Computer Integrated Manufacturing 36 (6), 807-829 , 2023 2023 Citations: 11
Experimental study on affordable thermal insulation of exhaust manifolds using modified sheep wool waste P Sudalai, M Manoharan Materials Today: Proceedings , 2023 2023 Citations: 5
Collaborative motion synchronization for affordable open-source cobots M Manoharan, KSS Thilak, S Kumaraguru 2022 IEEE 6th Conference on Information and Communication Technology (CICT), 1-5 , 2022 2022 Citations: 7
Medial Axis Transformation Based Design and Process Planning Methodology for Discrete Multi-Material Additive Manufacturing M Manoharan, PHP Naidu, M Joy, S Kumaraguru International Design Engineering Technical Conferences and Computers and … , 2022 2022
Volume Decomposition of Faceted Models to Minimize Post-processing Issues for Multi-robots Collaborative Material Extrusion Systems M Manoharan, C Hareesh, S Kumaraguru Industry 4.0 and Advanced Manufacturing: Proceedings of I-4AM 2022, 37-46 , 2022 2022 Citations: 3
MOST CITED SCHOLAR PUBLICATIONS
Path planning for direct energy deposition with collaborative robots: A review M Manoharan, S Kumaraguru 2018 conference on information and communication technology (CICT), 1-6 , 2018 2018.0 Citations: 24
A novel volume decomposition methodology for multi-robots collaborative additive manufacturing M Manoharan, AN Shridhar, VY Vinod, S Kumaraguru 2020 IEEE 4th conference on information & communication technology (CICT), 1-6 , 2020 2020.0 Citations: 21
Statistical Modelling to Study the Implications of Coated Tools for Machining AA 2014 Using Grey Taguchi‐Based Response Surface Methodology M Manoharan, A Kulandaivel, A Arunagiri, MRA Refaai, S Yishak, ... Advances in Materials Science and Engineering 2021 (1), 6843276 , 2021 2021.0 Citations: 20
Novel process planning approach for support-free additive manufacturing using multi-axis deposition systems M Manoharan, S Kumaraguru International Journal of Computer Integrated Manufacturing 36 (6), 807-829 , 2023 2023.0 Citations: 11
Advances in Additive Manufacturing and Joining: Proceedings of AIMTDR 2018 MS Shunmugam, M Kanthababu Springer Nature , 2019 2019.0 Citations: 10
Industry 4.0 and Advanced Manufacturing A Chakrabarti, S Suwas, M Arora Proceedings of, 1-4 , 2024 2024.0 Citations: 8
A study on the corrosion behaviour of aluminium alloy 2014 T-651 friction stir welds using stress corrosion cracking T Kollapuri, M Manoharan, RB Sadayan, RKR Sajja ASME International Mechanical Engineering Congress and Exposition 57571 … , 2015 2015.0 Citations: 8
Collaborative motion synchronization for affordable open-source cobots M Manoharan, KSS Thilak, S Kumaraguru 2022 IEEE 6th Conference on Information and Communication Technology (CICT), 1-5 , 2022 2022.0 Citations: 7
Investigation of novel sustainable concrete using optimization technique V Subathra Devi, BK Gnanavel, P Murthi, M Madhanagopal Advanced Materials Proceedings 2 (2), 86-92 , 2017 2017.0 Citations: 7
Experimental study on affordable thermal insulation of exhaust manifolds using modified sheep wool waste P Sudalai, M Manoharan Materials Today: Proceedings , 2023 2023.0 Citations: 5
Tailored Support Structures for Additive Manufacturing HA Kumar, PF Reginald Elvis, M Manoharan, J Jayapal, S Kumaraguru Advances in Additive Manufacturing and Joining: Proceedings of AIMTDR 2018 … , 2019 2019.0 Citations: 5
Strength characteristics of steel fiber reinforced concrete with sugarcane bagasse ash and wood ash S Raghuram, M Manoharan, V Gayathri, R Thilahar Engineering Research Express 6 (4), 045116 , 2024 2024.0 Citations: 3
Investigation on influence of die electric medium in electrical discharge machining of monel 400 alloy M Manoharan, S Perumal, A Ajithram, SD Kumar, J Ekanthamoorthy Applied Mechanics and Materials 919, 3-10 , 2024 2024.0 Citations: 3
Experimental investigation of strength characteristics of concrete reinforcement with neem powders S Raghuram, M Manoharan, A Devanandhu Materials Today: Proceedings , 2023 2023.0 Citations: 3
Volume Decomposition of Faceted Models to Minimize Post-processing Issues for Multi-robots Collaborative Material Extrusion Systems M Manoharan, C Hareesh, S Kumaraguru Industry 4.0 and Advanced Manufacturing: Proceedings of I-4AM 2022, 37-46 , 2022 2022.0 Citations: 3
Electromyography (EMG) Signal Acquisition for Exoskeleton Control: Enhancing Precision in Human-Machine Interaction R Thilahar C, ... 2024.0 Citations: 2
Prediction of wear volume and friction coefficients of SS304 alloy using grey taguchi-based response surface methodology P Ponnuswamy, M Manoharan Materials Research Express 11 (6), 066515 , 2024 2024.0 Citations: 2
A Study on the Use of Functionally Graded Lattice Structures for Optimizing the Design of Femoral Prosthesis M Manoharan, GS Kaliaraj, P Sudalai, S Preethi, S Varghese International Conference on Additive Manufacturing, 89-99 , 2024 2024.0 Citations: 1
Investigation on environmentally polluted water hyacinth with banana fibre reinforced composite absorption properties A Ajithram, JT Winowlin Jappes, S Perumal, SD Kumar, M Manoharan Materials Science Forum 1112, 33-40 , 2024 2024.0 Citations: 1
Process planning for Multi-Robot and Multi-Axis Additive Manufacturing Processes' K Senthilkumaran INDIAN INSTITUTE OF INFORMATION TECHNOLOGY, DESIGN AND MANUFACTURING , 0 Citations: 1