A Bone Rasp is a medical device that is used by surgeons to clean out and hollow a femur bone before the insertion of a medical implant. The bent and tapering surface of the Bone Rasp allows it to fit well to the shape of the femur bone but does pose a big challenge for our software.

The aim was to replicate small 2mm x 2mm x 2mm pyramids onto the surface of the part in a helical form. Another level of complexity meant that the orientation of the pyramids had to change depending on the where they sat on the part itself. Though the Bone Rasp was built in a vertical direction and never dipped below 40 degrees to the build plane, pyramids on the downward facing surface would have to re-orientate themselves so as none of their surfaces dipped below 40 degrees.

The images above show a concept Bone Rasp that has been designed in collaboration with EOS and is for demonstration purposes only. Further improvements and modification to this design are due over the next couple of months, making the design better suited for real world use.