1. Nieuwe generatie van lichtgewicht mobiliteitsproducten en externe protheses Iedere gram telt… Geert Smits, Mifa Aluminium BV, Aalberts Industries NV

2. The Dutch population numbers 16.7 million inhabitants today 4,7% (± 800,000 people) of Dutch population need aids to enhance mobility Cain Crutch Walking frame Wheelchair 5,4% (± 900,000 people) of Dutch population use anatomic aids Orthopedic shoes Orthesis Prosthesis Data from CBS

3. Like everyone else Stay active Be independent Have a social life Have a professional career Participate in sports Mobility and anatomic aids Designed according to their individual needs Shape Size

4. …But everyone wants lighter aids Easier to lift / push Competitive advantageEnergy efficient

5. And stiffer. And more comfortable. More efficient transfer of muscle power Better absorbance of shocks

6. Translation of user requirements into the right material Light and strong - Specific Strength Material selection by the Ashby approach

7. Translation of user requirements into the right material Light and strong - Specific Strength 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Material selection by the Ashby approach

8. Translation of user requirements into the right material Light and strong - Specific Strength 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Light and stiff - Specific Stiffness 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Material selection by the Ashby approach

9. Translation of user requirements into the right material Light and strong - Specific Strength 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Light and stiff - Specific Stiffness 1. Magnesium Alloys 2. Aluminium Alloys 3. Titanium Alloys 4. Steels Shock absorbent - Specific Damping Capacity 1. Magnesium Alloys 2. Steels 3. Aluminium Alloys 4. Titanium Alloys Material selection by the Ashby approach

10. Pros and cons of Magnesium 40% lighter than Aluminium 250% lighter than Titanium 400% lighter than Steel 30% better absorption of vibrations than Aluminium Low deformability at room temperature Low corrosion resistance No readily available technology for manufacturing Magnesium parts + -

11. Total Performance Approach ExtrusionMachiningBending Welding and assemblyFinished productCoating

12. Challenges: Extrusion Optimization of die design Optimization of billet homogenizing treatments Optimization of extrusion temperature and speed Determination of extrudate strength Challenges: bending Determination of minimum relative bending radius Optimization of bending speed Determination of spring-back Optimization of bending temperature

13. Bending at room temperature, speed 1 rpm

14. Bending at 150°C, speed 1 rpm

15. Challenges: Machining Optimization of feed rate Optimization of cutting speed Optimization of depth of cut Challenges: Coating Optimization of pretreatments Optimization of process parameters Optimization of lacquering step Wear resistance of coating Corrosion resistance of coating

16. Challenges: Welding and assembly Optimization of pre-treatments Optimization of filler feeding Optimization of alternating current Determination of joint strength Phase II: Manufacturing and biomechanical testing of prototypes Starts summer 2012 Selection of prototypes Design of prototypes Manufacturing of prototypes Biomechanical testing of prototypes

17. Sharon Walraven Silver medalist – Olympic Games Sydney 2000 (Ladies single) Gold medalist – Olympic Games Beijing 2008 (Ladies double) Phase II: Manufacturing and biomechanical testing of prototypes Novel ultra-light wheelchair for tennis-star Sharon Walraven

18. Future spin-offs after completion of the project Light-weight magnesium coated profiles and parts for High end sport bikes Automobiles Airplanes Portable electronics

19. The members of the consortium would like to thank …..