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This research presents a subtractive rapid manufacturing process for heterogeneous materials, in particular for custom shaped bone implants. Natural bone implants are widely used in the treatment of severe fractures or in tumor removal. In order for the human body to accept the bone implant material and heal properly, it is essential that the bone implant should be both mechanically and biologically compatible. Currently, the challenge of having correctly shaped natural bone implants created from an appropriate material is met through hand-shaping done by a surgeon. CNC-RP is a rapid machining method and software that can realize a fully automated Subtractive Rapid Prototyping (RP) process, using a 3-axis milling machine with a 4 axis indexer for multiple setup orientations. It is capable of creating accurate bone implants from different clinically relevant material including natural bone. However, there are major challenges that need to be overcome in order to implement automated shape machining of natural bones. They are summarized as follows: (1) Unlike homogeneous source materials for which a part can be machined from any arbitrary location within the original stock, for the case of donor bones, the site and orientation of implant harvest need to consider the nature of the heterogeneous internal bony architecture. (2) For the engineered materials, the source machining stock is in the convenient form of geometrically regular shapes such as cylinders or rectangular blocks and the entities of sacrificial supports can connect the part to the remaining stock material. However,

Process planning for the subtractive rapid manufacturing of heterogeneous materials: Applications for automated bone implant manufacturing