Cam Simulation and Dimensional Verification of CNC-Machined Orthopaedic Femoral Components: Toolpath Optimization and 3D-Scan Metrology

Authors

DOI:

https://doi.org/10.26877/asset.v8i2.2760

Keywords:

CAM simulation, 5-axis CNC, total knee replacement (TKR), 3D scanning, RMS deviation, dimensional metrology

Abstract

This study investigates the optimization of manufacturing femoral components for Total Knee Replacement (TKR) using Computer-Aided Manufacturing (CAM) simulation and 5-axis CNC milling, followed by dimensional verification based on 3D scanning. The machining process was simulated in Autodesk PowerMill to generate collision-free toolpaths for AISI 316L stainless steel. Dimensional verification was conducted by comparing the 3D-scanned physical model (using Creality CR-Scan Ferret Pro) with the original CAD model in Geomagic Control X. The metrological analysis showed a Root Mean Square (RMS) deviation of 0.5317 mm and an average positive deviation of 0.2572 mm. Spatial deviation analysis revealed significant dimensional variations, with a maximum deviation of +2.5761 mm and a minimum deviation of -2.5713 mm. Specifically, in critical functional regions, the medial and lateral condyles exhibited deviations ranging from -0.4683 mm to 0.232 mm, while the patellar groove showed a deviation of 0.1989 mm. Although the machining strategy successfully produced the complex implant geometry, the tolerance distribution data indicated that only 17.22% of the surface fell within the strictly specified tolerances, highlighting the need for further optimization of cutting parameters and fixturing strategies to minimize surface roughness and dimensional inaccuracies.

Author Biographies

  • Yuris Setyoadi, Universitas Persatuan Guru Republik Indonesia Semarang

    Faculty of Engineering and Informatics, Universitas PGRI Semarang, Jl. Sidodadi-Timur No.24 Semarang, Central Java, 50232, Indonesia

    Department of Mechanical Engineering, Faculty of Engineering, Diponegoro University, Semarang, Central Java, 50275, Indonesia

  • Rifky Ismail, Diponegoro University

    Department of Mechanical Engineering, Faculty of Engineering, Diponegoro University, Semarang, Central Java, 50275, Indonesia

    Center for Bio-Mechanics Bio-Material Bio-Mechatronics and Bio-Signal Processing (CBIOM3S) Central Java, 50275, Indonesia

  • Athanasius Priharyoto Bayuseno, Diponegoro University

    Department of Mechanical Engineering, Faculty of Engineering, Diponegoro University, Semarang, Central Java, 50275, Indonesia

    Center for Bio-Mechanics Bio-Material Bio-Mechatronics and Bio-Signal Processing (CBIOM3S) Central Java, 50275, Indonesia

  • I Nyoman Jujur, Badan Riset dan Inovasi Nasional

    Center for Advanced Materials Research OR Nanotechnology and Materials-BRIN, Jl. M.H. Thamrin No. 8, Jakarta Pusat 10340, Indonesia

  • Robin Novriansyah, Dr. Kariadi Hospital

    Department of Orthopaedic and Traumatology, Dr. Kariadi Hospital, Semarang, Central Java, 50244, Indonesia

  • Darmanto, Wahid Hasyim University

    Department of Mechanical Engineering, Faculty of Engineering, Wahid Hasyim University, Semarang, Central Java, 50232, Indonesia

  • Hartanto Prawibowo, Semarang State Polytechnic

    Department of Mechanical Engineering, Semarang State Polytechnic, Semarang, Central Java, 50275, Indonesia

  • Paulus Wisnu Anggoro, University of Atma Jaya Yogyakarta

    Department of Industrial Engineering, Faculty of Industrial Technology, University of Atma Jaya Yogyakarta, Yogyakarta, 55281, Indonesia

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Published

2026-03-31

Issue

Vol. 8 No. 2 (2026): February-April

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Articles

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