Implant and method for covering large-scale bone defects for thorax

Abstract

To provide an improved implant, particularly an implant for covering large-scale bone defects for a thorax.SOLUTION: Provided is an implant 400 for covering a thorax bone defect, comprising: at least one lattice structure 440-1, 440-2 of individual lattice cells 410-1, 410-2, 410-3, each lattice cell comprising one or more ring elements 120, each ring element comprising a through-hole configured for receiving a fixation device, at least some of the ring elements being connected via nonlinear bridge elements 432 to one another, wherein the implant is made at least predominantly from a plastic material.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to an implant and a method for covering large bone defects, in particular in the thorax. The covering of a bone defect involves in particular bridging the bone defect, i.e. providing a connection or link between the bone parts remaining in the patient's body. [Background technology]

[0002] To cover large bone defects in the thorax, so-called rib plates are usually used. Rib plates are usually elastic strips with through holes (or orifices) for receiving fixation devices such as bone screws. Rib plates can be provided as hardened, semi-hardened or malleable and are usually fixed to and bridge the remaining parts of the patient's ribs. However, in some cases, additional support to the areas between the different ribs can be beneficial for the treatment.

[0003] Metal mesh-grid implants are known for treating skull defects, as described, for example, in U.S. Patent No. 5,468,242. Such mesh-grid implants provide the necessary flexibility to conform to the curvature of the skull while remaining sufficiently elastic.

[0004] In the thoracic region, flexibility is important to accommodate various curvatures, while the constant motion of the thorax due to breathing or movement of the patient poses an additional challenge, while at the same time preventing injury to internal organs, especially vital organs such as the heart, lungs, and major blood vessels that are normally protected by the thorax.

[0005] Thoracic trauma is damage to the bones and / or organs or organ systems of the chest, often in a life-threatening manner. One of the most common thoracic injuries is a rib fracture. Rib fractures can usually be treated with metal implants and bone regeneration. K-wire osteosynthesis using so-called K-wires ("Kirschner wires") is also known. However, these tend to move after implantation, especially in the bone cavity, and may break. Furthermore, the use of K-wires often requires an additional cast, which complicates the treatment of thoracic trauma.

[0006] Furthermore, the use of metal rails or rib plates is also known, for example in DE 3803435 C1 a rail implant with sides adapted to the contours of the patient's ribs is disclosed, this solution being an improvement over stiffness which may affect breathing. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Pat. No. 5,468,242 [Patent Document 2] German Patent No. 3803435C1 Summary of the Invention [Problem to be solved by the invention]

[0008] One object of the present invention is to provide an improved implant, particularly for covering large bone defects in the thorax. Another object is to provide an implant that is highly resistant to material failure, does not cause pain and aids healing, and allows controlled movement in the defect area.

[0009] Still another object is to provide improved methods for manufacturing such implants, improved methods for covering large bone defects, and other improved products related thereto.

[0010] Said object is solved by the subject matter of the independent claims.

[0011] Thus, a first aspect of the present invention provides an implant for covering a bone defect in the thorax, comprising at least one lattice structure having a plurality of individual lattice cells, each of the plurality of lattice cells having one or more ring members, the ring members having through holes configured to receive (or be capable of receiving) a fixation device, at least some of the ring members in the lattice structure being connected to each other via linear or non-linear bridge members, the implant being at least primarily made from a plastic material.

[0012] This provides an implant, preferably made of one or more polymers, for treating small or large thoracic bone defects. The implant can be easily secured to bone (e.g., ribs) in any of many different positions and locations, according to the surgeon's judgment, by utilizing the ring members and the through holes. Furthermore, the implant can be bent about one or more twisting and / or bending axes. The implant is particularly suitable for large thoracic bone defects. In this specification, a large bone defect is defined as a bone defect having an area larger than one parallel millimeter, particularly a planar bone defect having an area larger than 1000 square millimeters, such as 25 square centimeters, 100 square centimeters, or 900 square centimeters.

[0013] The implant is also well suited for treating curved bone defects, and even irregularly shaped bone defects, since the implant can be adapted by the surgeon, even during surgery, to the specific size and shape of the defect, e.g., by removing (or cutting) excess portions of the implant.

[0014] In an advantageous configuration, the bridge member is 20 mm 2It has a smaller cross-sectional area, which allows it to be easily cut using common surgical instruments.

[0015] The lattice structure may be a two-dimensional implementation of a triclinic lattice, a monoclinic lattice, an orthorhombic lattice, a tetragonal lattice, a hexagonal lattice, or a cubic lattice.

[0016] The implant can have 10, 50, or even more than 100 ring members and a corresponding number of through holes, giving the surgeon many options as to where to place the fixation devices and to which portions of the patient's bone the implant is secured.

[0017] A second aspect of the invention provides a system for covering large bone defects comprising any of the implants according to the first aspect and a number of fixation devices.

[0018] The fixation devices may have the same or different configurations relative to one another, the fixation devices may include or consist of the same or different materials as the implant, and fixation devices include relatively simple bone screws, although more complex fixation devices, such as those secured by ultrasonic welding, may also be used.

[0019] A third aspect of the present invention provides a method for covering a thoracic bone defect, in particular a large thoracic bone defect, comprising the steps of providing an implant according to any embodiment of the first aspect of the invention and at least two fixation devices or a system according to any embodiment of the second aspect of the invention, and fixing the implant to at least two portions of a patient's bone using the fixation devices.

[0020] A fourth aspect of the invention provides a method of manufacturing an implant according to any embodiment of the first aspect of the invention, comprising total additive manufacturing or injection moulding of said implant. Manufacturing the implant may comprise first shaping the implant and then reshaping the implant to a desired shape, e.g. to produce a curved feature or part.

[0021] The production of implants by injection molding is - (optionally) preforming an implant body mould; - injecting a plastic material, preferably a polymeric material, into said implant body mould; - cooling and cross-linking the injected material; may include.

[0022] A fifth aspect of the invention provides a computer readable non-volatile data storage medium storing data defining a digital representation of an implant according to any embodiment of the first aspect of the invention.

[0023] A sixth aspect of the invention provides a computer readable non-volatile data storage medium storing data defining a digital representation of an implant according to any embodiment of the first aspect of the invention, said data storage medium may be a solid state memory, a magnetic hard drive or magnetic hard disk drive, a solid state drive or solid state drive circuitry, a CD, a DVD, a Blu-ray, etc.

[0024] A seventh aspect of the invention provides a data stream comprising, or configured to generate, data defining a digital representation of an implant according to any embodiment of the first aspect of the invention.

[0025] In an embodiment of any of the fifth, sixth or seventh aspects, the data may include operating instructions configured to control an additive manufacturing machine to manufacture the implant using a digital representation of the implant when the data is sent to the additive manufacturing machine.

[0026] Further, particular advantageous embodiments, variants, optional configurations and embodiment improvements are evident from the description and the accompanying drawings, as well as the dependent claims. In particular advantageous embodiments, variants or embodiment improvements, the implant is made from a plastic material using additive manufacturing AM and / or injection moulding. This provides a comprehensive and easy way to manufacture implants with desired properties such as hardness and flexibility.

[0027] In certain advantageous embodiments, variants or improvements of the embodiments, the implant is formed from materials including or consisting of polyetheretherketone, PEEK, polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum and / or composites thereof.

[0028] In certain advantageous embodiments, variations or refinements of the embodiments, the implant is formed from a material comprising or consisting of hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium containing composites, which provide a desired balance between weight, hardness, flexibility and medical properties.

[0029] In certain advantageous embodiments, variants or refinements of the embodiments, at least one lattice structure has antibacterial properties. This supports the healing process. Other parts of the implant, such as the burr units (see below), may also be provided with antibacterial properties. Preferably, the entire implant has antibacterial properties.

[0030] In certain advantageous embodiments, variations or refinements of the embodiments, the at least one lattice structure has a thickness of about 0.1 mm to about 0.5 mm.

[0031] In certain advantageous embodiments, variants or improvements of the embodiments, the lattice structure is a substantially two-dimensional lattice, in particular a triclinic lattice, a monoclinic lattice, an orthorhombic lattice, a tetragonal lattice, a hexagonal lattice or a cubic lattice.

[0032] In certain advantageous embodiments, variations or refinements of the embodiments, at least a number of the lattice cells comprise a single link member having at least a portion of at least one bridge member.

[0033] In certain advantageous embodiments, variants or refinements of the embodiments, all connections between all ring members (especially all bridge members) are non-linear.

[0034] In a particular advantageous embodiment, variant or refinement of the embodiment, the implant comprises at least one low density lattice cell LDLC and at least one high density lattice cell HDLC having the same size and shape as the at least one lattice cell LDLC but with more ring members, in which case the properties of different parts of the implant will be different relative to each other, for example the high density lattice cell parts will be stronger and provide more robust support, while the low density lattice cell parts will be more flexible.

[0035] In certain advantageous embodiments, variants or improvements of embodiments, the implant comprises at least one lattice structure and at least one bar unit, the lattice structure and the bar unit being arranged in a regular pattern. The lattice structure and the bar unit may be arranged in an alternating manner. The lattice cells adjacent to a bar unit may be connected to the bar unit by linear bridge members (although non-linear bridge members are also possible).

[0036] In certain advantageous embodiments, variants or refinements of the embodiments, the implant is characterized in that the bridge members connecting the ring members in a direction parallel to the longitudinal direction of the at least one bar unit are straight bridge members, which provides additional support in the longitudinal direction while maintaining flexibility in a direction perpendicular to the longitudinal direction.

[0037] In a particular advantageous embodiment, variant or refinement of the embodiment, the implant comprises a number of bar units arranged in an offset state with respect to one another.

[0038] In a particular advantageous embodiment, variant or embodiment refinement, the implant comprises a number of bar units arranged parallel to one another and precisely aligned with respect to their longitudinal ends.

[0039] In certain advantageous embodiments, variants or refinements of embodiments, the burr unit has at least one row of through holes for receiving fastening devices, the at least one burr unit has a plurality of through hole pairs, the through hole pairs being arranged along a longitudinal axis of the burr unit, the through hole pairs of the plurality of through hole pairs being arranged parallel to each other, but non-parallel and non-perpendicular to the longitudinal axis of the at least one burr unit.

[0040] In certain advantageous embodiments, variants or refinements of the system according to the second aspect of the invention, the fixation device comprises or consists of biodegradable or non-biodegradable metal screws or pins, or absorbable or non-absorbable polymer pins or screws.

[0041] In a particular advantageous embodiment, variant or refinement of the method according to the third aspect of the invention, the at least two portions of bone are part of one or more ribs, said one or more ribs being partially missing.

[0042] In a particular advantageous embodiment, variant or embodiment refinement of the method according to the third aspect of the invention, the system comprises an implant having at least one bar unit, the implant being fixed to at least one rib of the patient by one or more ring members in at least one lattice structure, whereby the at least one bar unit substitutes for a missing portion of at least another rib of the patient.

[0043] In a particular advantageous embodiment, variant or embodiment refinement of the method according to the third aspect of the invention, the implant is tailored, after manufacture, particularly to a particular patient and / or a particular bone defect by removing part of at least one lattice structure. [Brief description of the drawings]

[0044] The present invention will now be described in detail with reference to exemplary embodiments thereof as illustrated in the accompanying drawings. The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and form a part of the specification. The drawings illustrate embodiments of the invention and, together with the detailed description, explain the principles of the invention. Other embodiments of the invention and many of the intended advantages of the invention will be better understood and more readily appreciated by reference to the detailed description that follows. Elements in the drawings are not necessarily scaled relative to one another. Corresponding like parts are designated with the same reference numerals.

[0045] [Figure 1A] FIG. 1A shows an implant for covering a large bone defect according to one embodiment of the present invention. [Figure 1B]FIG. 1B shows a variation of the embodiment of FIG. 1A. [Figure 1C] FIG. 1C shows another variation of the embodiment of FIG. 1A. [Diagram 2] FIG. 2 shows an implant according to another embodiment of the present invention. [Diagram 3] FIG. 3 shows an implant according to yet another embodiment of the present invention. [Figure 4] FIG. 4 shows an implant according to yet another embodiment of the present invention. [Diagram 5] FIG. 5 shows an implant according to yet another embodiment of the present invention. [Figure 6] FIG. 6 shows an implant according to yet another embodiment of the present invention. [Figure 7] FIG. 7 shows an implant according to yet another embodiment of the present invention. [Figure 8] FIG. 8 shows an implant according to yet another embodiment of the present invention. [Figure 9] FIG. 9 shows an implant according to yet another embodiment of the present invention. [Figure 10] FIG. 10 illustrates an implant according to yet another embodiment of the present invention. [Figure 11] FIG. 11 shows an implant according to yet another embodiment of the present invention. [Figure 12] FIG. 12 illustrates an implant according to yet another embodiment of the present invention. [Figure 13] FIG. 13 shows an example of application of the implant of FIG. [Figure 14] FIG. 14 shows an example application of the implant of FIG. 1A. [Figure 15] FIG. 15 shows a schematic of a system with an implant and a fixation device. [Figure 16] FIG. 16 shows a schematic flow diagram illustrating a method for covering a bone defect, according to one embodiment. [Figure 17]FIG. 17 shows a schematic flow diagram illustrating a method of manufacturing an implant according to one embodiment. [Figure 18] FIG. 18 shows a schematic block diagram illustrating a data storage medium according to one embodiment of the present invention.

[0046] In the drawings, unless otherwise noted, like or functionally similar components are numbered the same. Orientational terms such as "top," "bottom," "left," "right," "upper," "lower," "horizontal," "vertical," "rear," "front," "row," and "column," and the like, are used for descriptive purposes only and are not intended to limit the embodiments to the particular configurations illustrated in the drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] While specific embodiments are shown and described, it will be understood by those skilled in the art that various alternative or equivalent implementations may be made to the specific embodiments shown and described without departing from the spirit and scope of the present invention. This application encompasses various improvements or modifications of the specific embodiments described.

[0048] 1A shows an implant 100 for covering a large bone defect according to one embodiment of the present invention. In this embodiment, the implant 100 includes a single lattice structure 140 having individual cells 110-1, 110-2, 110-3, and 110-4 (hereinafter sometimes collectively referred to as 110-i). The lattice structure 140 has a two-dimensional hexagonal base structure, with each lattice cell 110-i having a hexagonal shape, with each corner of the hexagonal shape being formed by a ring member 120. As mentioned above, it should be understood that the lattice structures described herein may be formed with various types of periodic lattice patterns, in particular triclinic, monoclinic, orthorhombic, tetragonal, pyramidal, hexagonal, or rectangular lattice patterns.

[0049] Each ring member 120 has a through hole (or orifice) for receiving a fixation device such as a bone screw or pin. For example, the size of the through hole or the diameter of the ring member 120 can be between 0.1 mm and 5.5 mm.

[0050] The "ring member" in this specification does not have to have a circular outer shape. That is, the entire ring member 120 does not have to have a ring shape. It may also be a square or oval shape with a circular through hole. However, the ring member 120 is preferably circular because it is at least in contact with the tissue that it covers.

[0051] The ring members 120 are connected to one another by a generally S-shaped, non-linear bridge member 130. The curvature of the bridge member 130 changes direction at least in one place, preferably at a central point which acts as a bend point.

[0052] 1A, lattice cells 110-1, 110-2, 110-3 at the outer edge of lattice structure 140 differ slightly from lattice cell 110-4, which is located entirely within lattice structure 140, with respect to bridge members 130 not present at the outer edge of lattice structure 140. Apart from this difference, all lattice cells 110-i are identically shaped (as in depicting a quartz crystal, which has a slightly different configuration at the outer edge) so that lattice structure 140 can be viewed as a lattice of hexagonal base structures.

[0053] 1A further illustrates that a portion of lattice structure 140 may belong to multiple lattice cells 110-i. For example, one ring member 120 belongs to each of lattice cells 110-1, 110-2, and 110-4.

[0054] In the configuration of implant 100 of FIG. 1A, each of the lattice cells 110-i (or unit cells, or lattice unit cells) has a hexagonal outer shape, with the lattice cells 110-i having ring members 120 directly connected to each of the adjacent ring members 120 disposed along the hexagonal outer shape via non-linear bridge members 130. Each of the lattice cells 110-i further includes a central ring member 120 disposed in the center of the hexagonal outer shape of the cell, apart from the six members that form the hexagonal outer shape of the cell. In the configuration shown, the central ring member 120 is directly connected to only two of the six other ring members 120 that are disposed diagonally opposite one another.

[0055] It will be appreciated that the particular configuration shown in Figure 1A is particularly advantageous because it provides a relatively rigid adaptive lattice structure 140. In certain variations, some of the rigid stems or some of the bridge members from the central ring member 120 may be omitted.

[0056] As mentioned above, the entire lattice structure 140 or the entire implant 100 may be formed from materials having or consisting of polyetheretherketone, PEEK (polyetheretherketone), PE, polyethylene, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0057] In the configuration of FIG. 1, the entire lattice structure 140 is generally rectangular in shape, with the width varying within a range of up to half the width of one lattice cell 110-i.

[0058] The implant 100 (and more particularly the lattice structure 140 of the implant 100) may have a thickness between 0.1 mm and 5 mm, preferably between 1 mm and 3 mm, and may further be antibacterial. One or both of the planar surfaces of the implant, and more particularly the lattice structure 140, may be roughened to improve the integration of living cells on or within the surface.

[0059] 1B shows a modified version 100' of implant 100, which includes a lattice structure 140' with the same lattice alignment and the same individual lattice cells 110-i as lattice structure 140, but with a different overall shape than lattice structure 140. In the modified version of FIG. 1B, lattice structure 140' has alternating long strips 141-1, 141-2, ..., 141-8 and short strips 142-1, 142-2, ..., 142-8. Long strips 141-i are longer than short strips 142-i.

[0060] The short and long strips each have the width of one lattice cell 110-I, are arranged alternately and parallel to one another, starting with the long strip 141-1 and ending with the short strip 142-8. The long strips 141-i are arranged symmetrically with respect to the short strips 142-i, and in the illustrated variant, each side of the long strip 141-i is longer than the short strips 142-i by 2.5 lattice cells 110-i.

[0061] For example, elongated strips 141-i may be utilized to be secured to the patient's ribs on one or both sides, similar to a prior art rib plate.

[0062] FIG. 1C shows another variation 100″ of the implant 100′. The implant 100″ has a lattice structure 140″ with the same lattice alignment structure and the same individual lattice cells 110-i as the lattice structures 140, 140′, but with a different overall shape. The lattice structure 140″ has five long strips 141-1, . . . , 141-5 and six short strips 142-1, . . . , 142-6 arranged in parallel and alternating fashion, starting with the short strip 142-1 and terminating with the short strip 142-6. The other configurations of the long and short strips are similar to those described above with reference to FIG. 1B.

[0063] The aforementioned material selection allows the physician to - literally - adapt the implant 100, 100', 100'' to the patient during the medical procedure. For example, the implant 100'' is obtained by taking the implant 100' and cutting with scissors or a knife the three long strip portions 141-1, 141-2, 141-3 and the two short strip portions 142-1, 142-2.

[0064] FIG. 2 illustrates an implant 200 according to another embodiment of the present invention. The implant 200 includes a lattice structure 240 of hexagonal lattice cells 210-1, 210-2, ..., 210-i arranged in a hexagonal shape. In contrast to the lattice cell 110-i of FIGS. 1A-1C, the lattice cell 210-i includes only six ring members 120 forming a hexagonal outer shape, and does not include a central ring member. Therefore, the lattice structure 240 of FIG. 2 generally has a lower stiffness than the lattice structures of FIGS. 1A-1C.

[0065] However, the implant 200 has a number of bar units 250-1, 250-2, ..., 250-5 arranged in parallel at regular intervals and crossing the (empty) center of every two rows of lattice cells 210-i. The bar units 250-i provide additional elasticity, especially for elongation in the longitudinal direction of the busbar unit 250-i, while providing freedom of movement, e.g., shearing, in other directions. For example, the bar units 250-i may have a thickness between 0.5 mm and 5 mm. Ideally, they are thicker than the lattice structure 240, which can provide additional stability to the implant 200.

[0066] The entire implant 200 or various portions thereof, such as the bar units 250-i and / or the lattice structure 240, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0067] 3 shows an implant 300 according to another embodiment of the invention. The implant 300 comprises two variants of a lattice structure 340 arranged in a hexagonal shape. The strips 341-1, 341-2, ..., 341-5 of a first type and the strips 342-1, 342-2, ..., 342-5 of a second type are arranged alternately and parallel to each other.

[0068] The overall structure is the same as that of the implant 100 in Fig. 1A, and the first type strip portion 341-1 has the lattice cells 311-1, 311-2 (i.e., the same configuration as the lattice 210-i) of the implant 200 of Fig. 2 type, while the second type strip portion 342-1 has the lattice cells 312-1, 312-2 (i.e., the same configuration as the lattice cell 110-i) of the implant 100 of Fig. 1A type. In comparison, the lattice cells 312-i are indicated as high density lattice cells HDLC, and the lattice cells 311-i are indicated as low density lattice cells LDLC, because the HDLC 312-i has the same size and shape (shape of the outline) as the LDLC 311-i, but has a greater number of ring members 120 (one more in this example). Thus, the density of through holes per area and / or the material density per area (both in this example) is higher for HDLC than for LDLC.

[0069] As previously mentioned, implant 300 begins at one end with a first type strip portion 341-1 and ends at the other end with a second type strip portion 342-5 (or vice versa, depending on what is defined as the start and end points), but it is possible for implant 300 to both end and start at either type of strip portion.

[0070] The lattice cells 311-i (or the first type of lattice cells) of the first type of strip portion 341-i are more flexible than the lattice cells 312-i (or the second type of lattice cells) of the second type of strip portion 342-i. Thus, the implant 300 provides an effective balance of flexibility and rigidity. The ratio of the first and second type of strip portions can be changed according to the needs of each bone defect. For example, one second type (or rigid type) strip portion 342-i can be placed after every one first type (or flexible type) strip portion 341-i, after every two, after every three. Similarly, two second type (or rigid type) strip portions 342-i can be placed after every one first type (or flexible type) strip portion 341-i, after every two, after every three.

[0071] The implant 300 of Fig. 3 can be combined with any of the previous figures, in particular with the variants described in Fig. 1B and Fig. 1B. The first type of strips 341-i or the second type of strips 342-i can be configured as long and short strips, respectively, or vice versa. Preferably, the more elastic second strips 342-i are configured as long pieces, fulfilling some functions of a conventional rib plate, while the more flexible first type of strips 341-i can be placed between the second type of strips as short strips.

[0072] The entire implant 300 or various portions thereof, such as the strips 341-i, 342-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK, polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0073] 4 shows an implant 400 according to yet another embodiment of the present invention. The implant 400 has two separated lattice structures 440-1, 440-2, each of which is sandwiched by a bar unit 450-1, 450-2, 450-3 located at each end.

[0074] The bar units 450-i are arranged parallel to each other. That is, the longitudinal axes LA-1, LA-2, and LA-3 are parallel to each other. Furthermore, in the implant 400, the bar units 450-i are arranged offset with respect to their longitudinal ends, as shown by the angle 445 in FIG. 4. The angle 445 is defined between any of the longitudinal axes LA-1 and a line connecting the outermost points on one end side of each of the bar units 450-i. The angle 445 may be 90° (angle 90) in a particular variant. In the illustrated embodiment, the angle is greater than 45° and less than 90°, but may be between 60° and 90°, preferably between 75° and 90°.

[0075] The bar units 450-i are preferably formed as rib plates as known in the art. The bar units may be rigid, flexible, or have properties in between. One important application of the bar units is to be fixed to the remaining ribs of the patient. In the implant 400, each bar unit 450-i has a number of pairs of through holes 451-2. The pairs 451-i are arranged parallel to each other and at a predetermined angle to the longitudinal axis LA-i of the bar unit 450-i. The predetermined angle is between 30° and 90°, preferably 45°. The through holes of the bar units 450-i are the same size as the through holes of the ring member 120, so that the surgeon needs to prepare only one fixing device to fix the various through holes of the implant 400.

[0076] The lattice structures 440-1, 440-2 in the implant 400 are preferably of the same configuration, but in variants they may be of different configurations, for example with respect to the number of rows of lattice cells 410-i, where a row in this context should be understood to be a row of lattice cells 410-i arranged parallel to the longitudinal axis LA-i of the bar unit 450-i.

[0077] Similarly, in implant 400, each of lattice structures 440-1, 440-2 includes two rows of eight lattice units 410-i each, although other numbers of rows and numbers of lattice units 410-i per row are easily possible. In implant 400, each of lattice units 410-i includes a single ring member 120, which is connected by three or four bridge members 130, depending on whether the lattice units 410-i are located at the ends or interior of lattice structure 440-i, respectively. Bridge members 130 have an S-shape, as previously described. In particular, each bridge member 130 may be formed with two portions of opposite curvature to allow movement along the bridge member extending from one ring member 120 to the other ring member 120.

[0078] The lattice regularity of the lattice structure 440-i may be defined as cubic-body centered in two dimensions in plan view. Each ring member 120 is connected to each of its four (or three, if the ring member 120 in question is located at an edge of the lattice structure 440-i) adjacent members via one of the S-shaped bridge members 431.

[0079] The bridge members 432 connecting one lattice cell 410-i to one bar unit 450-i may be the same shape as the bridge members 432 between the lattices 410-i, or may be of a different configuration. In the lattice structure 440-2, the bridge members 432 connecting the lattice cell 410-i to the bar units 450-2, 450-3 are shown in FIG. 4 to have a different shape in that they have a straight portion between two opposite curvature portions.

[0080] It should be understood that implant 400 of Fig. 4 can have a variable number of bar units 450-i and can have any of lattice structures 140, 240, 341, 342, 440 sandwiched therebetween. In accordance with the above-mentioned variations, bar units 450-i can be changed to bar units 250-i of Fig. 2, and some or all of them can be short strips or (preferably) long strips of Fig. 1B or 1C, since all of these elements can be fixed to, cooperate with, replace or replace the patient's ribs or residual pieces of the ribs. Examples of these are described below.

[0081] The entire implant 400 or various portions thereof, such as bar unit 450-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0082] Fig. 5 shows an implant 500 according to yet another embodiment of the invention. The implant 500 can be seen as a variant of Fig. 4, modified in two respects. First, the bar units 550-1, 550-2, 550-3 of the implant 500 are not only arranged parallel but are also aligned with respect to one another in a direction perpendicular to the longitudinal axis LA-i of the bar unit 550-i.

[0083] Secondly, the lattice structures 540-1, 540-2 differ from the lattice structure of the implant 400 in that the bridge members 532 between the same row of lattice cells 510-i (or between the ring members 120) have a linear shape, i.e., a thin shaft shape. A row of such lattice cells 510-i, together with the linear (or straight) bridge members 532 between them, can be defined as a (smaller) bar unit. That is, the implant 500 can be defined as consisting of two different types of bar units (a long type having two rows of through holes and a short type having one row of through holes). Alternatively, the lattice structure 540-i can be recognized as having two lattice cells, i.e., a lattice cell of a bar unit having a linear arrangement of ring members 12 and a lattice cell connected by a straight bridge member.

[0084] In contrast, other bridge members 531 connecting lattice cells 510-i between different rows or connecting one lattice cell 510-i to one bar unit 550 may have a regular S-shape. It is clear that this configuration limits the flexibility of the implant 500 along the direction of the longitudinal axis LA-i while maintaining flexibility in the direction perpendicular to said direction.

[0085] The entire implant 500 or various portions thereof, such as the bar units 550-i and / or the lattice structure 540-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0086] FIG. 6 shows an implant 600 according to yet another embodiment of the present invention. The implant 600 can be recognized as a variation of the implant 500 of FIG. 5 because the two lattice structures 640-1, 640-2 have the same 2-dimensional cubic body-centered lattices as the lattice structure 540-i of the implant 500. However, the implant 600 has only a single bar unit 650, and each side of the bar unit 650 is connected to a lattice structure 640-i. The bridge members 532 connecting the ring members 120 along a direction parallel to the longitudinal axis LA of the bar unit 650 have a straight rod shape. The bridge members 531 connecting the ring members 120 along the other direction (here, the direction perpendicular to the longitudinal axis LA) have an S-shape, including the bridge members 531 connecting the ring members 120 to the bar unit 650.

[0087] As in implants 400 and 500, in implant 600 the length of bar units 450-i, 550-i, 650 extends beyond the attached lattice structure 440-i, 540-i, 640-i on both sides, for example by one, two, three or more pairs (as shown in Figures 4-6) of through-holes 451. In certain variations, bar units 450-i, 550-i, 650 can extend by different lengths on both sides of the lattice structure 440-i, 540-i, 640-i, or different bar units 450-i, 550-i, 650 in the same implant 400, 500, 600 can extend by different lengths or extend differently on both sides. One advantage of the protrusions is that the protrusions can be used to secure the bar units 450-i, 550-i, 650 to the patient's remaining rib portions so that the lattice structures 440-i, 540-i, 640-i cover the bone defects.

[0088] The entire implant 600 or various portions thereof, such as the bar unit 650 and / or the lattice structure 640-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0089] Fig. 7 shows an implant 700 according to yet another embodiment of the present invention. The implant 700 can be recognized as a variation of Fig. 4 in that the implant 700 has three bar units 750-1, 750-2, 750-3, with corresponding lattice structures 740-1, 740-2 sandwiched between each pair of the three bar units. The lattice structures 740-i are also two-dimensional cubic body-centered lattices, and the bridge members 731 connecting the ring members 120 are S-shaped as described above, similar to the bridge members 431 of the implant 400.

[0090] In contrast, the bridge members 732 connecting the ring members 120 to the bar units 750-i have a different shape. The bridge members 732 are straight and preferably shorter than the diameter of the ring members. This configuration provides additional stiffness between the bar units 750-i and the adjacent ring members 120, with stiffness gradually decreasing from the bar units 750-i towards the center of the lattice structure 740-i. This provides stiffness to the adjacent environment when the bar units 750-i are attached to the remaining portion of the rib, while the lattice structure 740-i between the bar units provides flexible support for the tissue.

[0091] The lattice structures 740-1, 740-2 of the implant 700 have five rows of lattice cells 710-i, each having eight lattice cells 710-i, which are arranged parallel to the longitudinal axis of the bar unit 750-i. In a different embodiment, the lattice structures 740-1, 740-2 have eight columns of lattice cells 710-i, each having five lattice cells 710-i, which are arranged perpendicular to the longitudinal axis of the bar unit 750-i and which are aligned on each side with adjacent through holes of the through hole pairs of the bar unit 750-i.

[0092] Because the two through holes of the through hole pair are angled relative to the longitudinal axis of the burr unit 750-i, the columns that are aligned with the through holes of the through hole pair on either side of the burr unit 750-i are misaligned with respect to each other and slightly displaced in the direction of the longitudinal axis. This configuration provides additional robustness to the implant 700 because there is no longer a "fault line" that runs perpendicular to the burr unit 750-i across the entire length of the implant 700.

[0093] Various modifications can be made to implant 700, such as having a different number of rows and / or columns of lattice cells 710-i, having bar units 750-i not protruding on either side (or protruding in a different configuration than shown), or having more or fewer bar units 750-i.

[0094] The entire implant 700 or various portions thereof, such as the bar units 750-i and / or the lattice structure 740-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0095] Fig. 8 shows an implant 800 according to yet another embodiment of the present invention. The implant 800 is a modification of the implant 700 of Fig. 7. The lattice regularity of the lattice structures 840-1, 840-2 is the same as that of the lattice structures 740-1, 740-2, and the lattice cells 810-i are configured identically to the lattice cells 710-i. The lattice cells 810-i are configured to have the same type of bridge members 731, 732 as the lattice cells 710-i of the implant 700, i.e., a straight bridge member 731 between the ring members 120 and the bar unit 850, and an S-shaped bridge member 731 between the ring members 120.

[0096] One point of contrast is that implant 800 has only a single bar unit 850, which has two lattice structures 840-1, 840-2 disposed on either side (sandwiched by two lattice structures 840-1, 840-2).

[0097] The lattice structures 840-1, 840-2 have four rows of lattice cells 810-i, each having ten lattice cells 810-i, and the rows of lattice cells are arranged parallel to the longitudinal axis of the bar unit. In a different embodiment, the lattice structures 840-1, 840-2 have ten columns of lattice cells 810-i, each having four lattice cells 810-i, and each column is arranged perpendicular to the longitudinal axis of the bar unit 850-i and is aligned on each side with adjacent through-holes of the through-hole pairs of the bar unit 850-i. In this variation, the bar unit 850 does not protrude on either side of either of the two lattice structures 840-1, 840-2. Various modifications can be made to implant 800, such as having a different number of rows and / or columns of lattice cells 810-i, having bar units 850 protruding on either side, or having multiple bar units.

[0098] The entire implant 800 or various portions thereof, such as the bar unit 850 and / or the lattice structure 840-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0099] Fig. 9 shows an implant 900 according to yet another embodiment of the invention. The implant 900 is a variant of the implant 700 of Fig. 7. In comparison with the implant 700, the implant 900 is provided with two additional lattice structures 940-3, 940-4, in which all three bar units 750-i are sandwiched between the lattice structures or all three bar units 750-i are flanked by the lattice structures. The additional lattice structures 940-3, 940-4 have the same number of columns as the lattice structure 740-i of the implant 700, but have a smaller number of rows (two rows in the variant shown).

[0100] The entire implant 900 or various portions thereof, such as the bar units 750-i and / or the lattice structures 740-i, 940-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0101] FIG. 10 shows an implant 1000 according to yet another embodiment of the present invention. The implant 1000 is a modification of the implant 700 of FIG. 7. There are only two differences. The first difference is that compared with the bar units 740-i of the implant 700, the bar units 1050-1, 1050-2, 1050-3 of the implant 1000 do not protrude on either side of the lattice structure 740-i. The second difference is the number of lattice cells 710-i in the lattice structures 1040-1, 1040-2, each of which has 12 columns 1061-i, 1062-i of lattice cells 710-i, each of which has 5 lattice cells 710-i.

[0102] As shown in FIG. 10, columns 1061-i of lattice cells 710-i of the first lattice structure 740-1 are substantially aligned between corresponding through hole pairs 1051-i of the first bar unit 1050-1 and corresponding through hole pairs 1052-i of the second bar unit 1050-2, and more particularly, between adjacent through holes of corresponding through hole pairs 1051-i of the first bar unit 1050-1 and adjacent through holes of corresponding through hole pairs 1052-i of the second bar unit 1050-2. Furthermore, the columns 1062-i of the lattice cells 710-i of the second lattice structure 740-2 are substantially aligned between the corresponding through-hole pairs 1052-i of the second bar unit 1050-2 and the corresponding through-hole pairs 1053-i of the third bar unit 1050-3, and more particularly between adjacent through-holes of the corresponding through-hole pairs 1052-i of the second bar unit 1050-2 and adjacent through-holes of the corresponding through-hole pairs 1053-i of the third bar unit 1050-3. Thus, the bar units 1050-i each have (or consist of) twelve through-hole pairs 1051-j, 1052-j, 1053-j.

[0103] Figure 10 shows markings on (from the left) the eighth through hole pair 1051-8 in the first bar unit 1050-1, the eighth column 1061-8 in the first lattice structure 740-1, the eighth through hole pair 1052-8 in the second bar unit 1050-2, the eighth column 1062-8 in the second lattice structure 740-2, and the eighth through hole pair 1053-8 in the third bar unit 1050-3.

[0104] The entire implant 1000 or various portions thereof, such as bar units 1050-i and / or lattice structure 740-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0105] FIG. 11 shows an implant 1100 according to yet another embodiment of the present invention. The implant 1100 is another variation of the implant 700 of FIG. 7. As in the previous variation of the implant 700, the type and configuration of the bridge members are the same as the implant 700. The difference between the implant 1100 and the implant 700 is that the implant 1100 consists of a single bar unit 1150 and a single lattice structure 1140 attached to one side of the bar unit 1150. The lattice structure 1140 has eight columns of lattice cells 710-i, each column having four lattice cells 710-i. The bar unit 1150 protrudes on each side by one through-hole pair 1051-1, 1051-10, and therefore has (or consists of) ten pairs 1051-i.

[0106] The entire implant 1100 or various portions thereof, such as the bar unit 1150 and / or the lattice structure 1140, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0107] FIG. 12 shows an implant 1200 according to yet another embodiment of the present invention. The implant 1200 has a single bar unit 1250 sandwiched between lattice structures 1240-1, 1240-2 arranged on either side. Each lattice structure 1210-i has ten columns, each having four lattice cells 1210-i. All bridge members 1230, including bridge members between ring members 120 and bridge members between ring members 120 and bar unit 1250, have a straight shape. The bar unit 1250 has only one row of equally spaced through holes and is configured as a rectangular strip with rounded corners. Each column of the lattice structure 1240-i is aligned with a corresponding through hole of the bar unit 1250. The bar unit 1250 protrudes on both sides by the length of four through holes.

[0108] The entire implant 1200 or various portions thereof, such as bar units 1250-i and / or lattice structure 1240-i, may be formed from materials comprising or consisting of polyetheretherketone, PEEK (polyetheretherketone), polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof, and / or composites containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium.

[0109] FIG. 13 shows an example of application of the implant 800 of FIG. 8. It shows a human thorax 1 with a large bone defect 3. In particular, the large bone defect 3 is a large part (more than 10%) of missing ribs 5-6. The bone defect 3 is covered by two implants 800. The implants 800 are fixed to the two ribs 5-5, 5-7 adjacent to the bone defect 3 by means of fixation devices inserted into the through holes of the row of the outermost lattice 810-i of each of the two lattice structures 840-i of each implant 800. The two implants 800 are arranged in a substantially line with an angle between the longitudinal axes of the two implants defined by the natural curvature of the ribs 5-5, 5-7. The single bar unit 850 of each implant 800 is not fixed. It will be clearly understood that the two bar units 850 of the two implants are arranged in a substantially line to substitute for the missing part of the ribs 5-6 in the bone defect 3.

[0110] Fig. 14 shows an application example of the implant 100 of Fig. 1A. The thorax 1 of Fig. 14 has a larger bone defect 3 than that shown in Fig. 13, and the bone defect 3 has defect portions in multiple ribs, particularly at least five ribs 5-i. The mesh-like implant 100 is fixed to the multiple ribs 5-i by utilizing the through-holes 110-i of the ring member 120, and the area between the fixing portions is covered by the lattice structure 140.

[0111] Fig. 15 shows a system 10 for covering large bone defects according to an embodiment of the second aspect of the invention. The system 10 comprises at least one implant according to any embodiment of the first aspect of the invention, in particular at least one of the implants 100-1200 described above. The system 100 further comprises at least one, preferably at least two fixation devices 11. The fixation devices 11 are configured to be received in through holes (or orifices) of the implants 100-1200 for fixation of the implants 100-1200 to bone, i.e. to one or more bones (complete or partial bones) of a patient.

[0112] The fixation device 11 may be made of materials that include or consist of titanium, polymers, or a variety of other suitable materials. For example, the fixation device 11 may be a screw (e.g., a titanium screw) or a more complex device, for example, with sonic weldable portions. Any fixation device may have biodegradable or non-biodegradable metal screws or pins, or absorbable or non-absorbable polymer pins or screws.

[0113] FIG. 16 specifically illustrates a flow diagram of a method for covering a large bone defect 3 (such as either of the bone defects of FIG. 13 or FIG. 14) using any of the implants 100-1200 previously described.

[0114] In step S100, a system 10 according to any of the embodiments of the present invention, in particular a system comprising any of the implants 100-1200 described above and any suitable fixation device 11, is provided.

[0115] In step S300, the implants 100-1200 are fixed to at least two portions of a bone 5-i of a patient using a fixation device 11. The bone portions may be portions of one or more ribs 5-i of the patient that have been partially or completely resected.

[0116] The system 10 may, inter alia, comprise the implant 800 of Fig. 8, secured as shown in Fig. 13. In particular, the implant 100-1200 may comprise at least one bar unit 150-1250, the implant 100-1200 being secured to at least one rib 5-i of the patient by one or more ring members 120 of at least one lattice structure 14-1240, such that the at least one bar unit 150-1250 substitutes for at least a missing portion of another rib 5-6 of the patient. Similarly, implants 100-1200 have a first bar unit fixed generally along the patient's first rib 5-5 and a second bar unit fixed generally along the patient's second rib 5-7, while a third bar unit disposed between the first and second bar units is not fixed to a portion of bone 5-6, such that the third bar unit is roughly (or precisely) positioned in the area where the missing portion or rib is located and roughly (or precisely) along the same direction (see FIG. 13), thereby providing a substitute for the missing portion of rib 5-6 or a total substitute for the patient's missing rib.

[0117] In optional step S200, the implants 100-1200 prepared in step S100 are tailored after manufacture (specifically, after additive manufacture) to a specific shape for a specific bone defect 3 and / or a specific patient, for example by a surgeon using, for example, surgical scissors, a scalpel, and / or various other medical instruments, to remove at least a portion of the implant 100-1200. In particular, the removal of a portion of the implant 100-1200 includes the removal of a portion of at least one lattice structure.

[0118] FIG. 17 is a flow diagram that illustrates, in a schematic manner, a method according to an embodiment of the fourth aspect of the present invention, i.e. a method for manufacturing any of the implants according to the embodiments of the first aspect of the present invention.

[0119] The method comprises a step S10 of providing data defining a digital representation of an implant according to any of the embodiments of the present invention, in particular any of the implants 100-1200 or modified configurations thereof.

[0120] The method comprises a step S20 of additively manufacturing (or 3D printing) the implant based on the digital representation.

[0121] The data provided in step S10 includes operating instructions for controlling an additive manufacturing machine using the digital representation, which is then used in step S20. Additive manufacturing can be performed at print temperatures in excess of 180° C. and with print layers between 0.1 mm and 0.5 mm thick.

[0122] Preferably, the entire implant is manufactured in this manner using additive manufacturing methods.

[0123] Alternatively, step S20 may be a step of manufacturing the implants 100-1200 using injection molding.

[0124] 18 is a block diagram that diagrammatically represents a computer readable non-volatile data storage medium 70 according to a fifth aspect of the present invention. The data storage medium 70 comprises data 75 defining a digital representation of an implant according to any of the embodiments of the first aspect of the present invention. Optionally, the data 75 may further comprise operating instructions configured to control an additive manufacturing machine for manufacturing the implant based on the digital representation of the implant. memory

[0125] Here, in one embodiment, multiple units or components of the same type may be numbered by a reference such as "110" (shown by way of example only; various other alphanumeric references may be used) followed by a dash and a number to indicate the individual unit or component, such as 110-1, 110-2, etc. This is to distinguish the individual units / components from each other, and in some cases may be used specifically to indicate all of the units / components of the same type, such as "110-1, 110-2, ..., 110-8". The last letter may be designated as "110-N" without designating anything specific. Both all of the collective components and randomly selected single components may be designated by "110-i" without loss of generality, especially when describing characteristics common to all of them. The meaning of "i" may vary between paragraphs or sentences depending on the context. Where distinctions are important, other lower case letters (such as "j", "k", etc.) are used in a similar manner to "i" in descriptions such as "even numbered members 110-i and noble numbered members 110-j", etc. In other contexts indicating an entire type of unit / member, ignoring the distinction between the "-i"s of individual members, the "-i" may simply be omitted.

[0126] The present invention includes at least the following embodiments.

[0127] Embodiment 1: An implant for covering a bone defect in the thorax, comprising: at least one lattice structure having a plurality of individual lattice cells; each of the plurality of lattice cells having one or more ring members, the ring members having through holes configured to receive fixation devices; At least some of the ring members in the lattice structure are connected to one another via linear or non-linear bridge members; The implant is at least primarily made of a plastic material.

[0128] Example 2: The implant of embodiment 1, Implants formed from plastic materials using additive manufacturing methods AM and / or injection molding.

[0129] Embodiment 3: The implant of embodiment 1 or 2, Materials including, or implants formed from, polyetheretherketone, PEEK, polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof.

[0130] Example 4: The implant of any one of embodiments 1 to 3, An implant made of a material having a composite containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium, or a material consisting of these.

[0131] Fifth embodiment: The implant of any one of embodiments 1 to 4, An implant wherein at least one lattice structure has antibacterial properties.

[0132] Sixth embodiment: The implant of any one of embodiments 1 to 5, The implant, wherein at least one lattice structure has a thickness of about 0.1 mm to about 0.5 mm.

[0133] Seventh embodiment: The implant of any one of the first to sixth embodiments, The lattice structure is a substantially two-dimensional lattice, in particular a triclinic lattice, a monoclinic lattice, an orthorhombic lattice, a tetragonal lattice, a hexagonal lattice or a cubic lattice.

[0134] Eighth embodiment: The implant of any one of embodiments 1 to 7, An implant, wherein at least a plurality of the lattice cells comprises a single phosphorus member along with at least a portion of at least one bridge member.

[0135] Ninth embodiment: The implant of any one of embodiments 1 to 8, An implant wherein all connections between all of the ring members are non-linear.

[0136] Tenth embodiment: The implant of any one of embodiments 1 to 9, An implant comprising at least one low density lattice cell LDLC and at least one high density lattice cell HDLC having the same size and shape as said at least one lattice cell LDLC but having more ring members.

[0137] Eleventh embodiment The implant of any one of the first to tenth embodiments, An implant comprising at least one lattice structure and at least one bar unit, said lattice structure and said bar unit being arranged in a regular pattern.

[0138] Embodiment 12: 12. The implant of embodiment 11, The implant, wherein the lattice structures and the bar units are arranged in an alternating manner.

[0139] Thirteenth embodiment 13. The implant of embodiment 11 or 12, An implant in which the lattice cells immediately adjacent to a bar unit are connected to the bar unit by linear bridge members.

[0140] Fourteenth embodiment 14. The implant of any one of embodiments 11 to 13, An implant, wherein the bridge member connecting the ring members in a direction parallel to the longitudinal direction of the at least one bar unit is a straight bridge member.

[0141] Fifteenth embodiment 14. The implant of any one of embodiments 11 to 13, An implant comprising a plurality of bar units disposed in an offset relationship with respect to one another.

[0142] Sixteenth embodiment 16. The implant of any one of embodiments 11 to 15, An implant comprising a plurality of bar units arranged parallel to one another and precisely aligned with respect to their longitudinal ends.

[0143] Seventeenth embodiment 17. The implant of any one of embodiments 11 to 16, The burr unit has at least one row of through holes for receiving fixation devices.

[0144] Embodiment 18: 18. The implant of any one of embodiments 11 to 17, An implant wherein the at least one burr unit has a plurality of through hole pairs, the through hole pairs being disposed along a longitudinal axis of the burr unit.

[0145] Embodiment 19: 19. The implant of embodiment 18, An implant wherein the through hole pairs of the plurality of through hole pairs are arranged parallel to each other in the plurality of through hole pairs, but are neither parallel nor perpendicular to the longitudinal axis of the at least one bar unit.

[0146] Twenty-first embodiment A system for covering large bone defects, comprising: A system comprising an implant of any one of embodiments 1 to 19 and a plurality of fixation devices.

[0147] Twenty-first embodiment A system according to a twentieth embodiment, The fixation device may be a system comprising biodegradable or non-biodegradable metal screws or pins, or absorbable or non-absorbable polymer pins or screws.

[0148] Twenty-second embodiment: 1. A method for covering a bone defect in a thorax, comprising: A system according to embodiment 20 or 21 is provided; A method of fixing the implant to at least two portions of a patient's bone using the fixation device.

[0149] Twenty-third embodiment A covering method according to embodiment 22, comprising: A method of covering, wherein the at least two portions of the bone are part of one or more ribs, the one or more ribs being partially missing.

[0150] Twenty-fourth embodiment A cover method according to embodiment 22 or 23, comprising: The system comprises an implant according to embodiment 10 having at least one bar unit, The implant is fixed to at least one rib of the patient by one or more ring members in at least one lattice structure, thereby covering at least one bar unit to substitute for a missing portion of at least another rib of the patient.

[0151] Twenty-fifth embodiment A cover method according to any one of embodiments 22 to 24, comprising: A method of covering whereby the implant is tailored, after manufacture, specifically to a particular patient and / or a particular bone defect by removing a portion of at least one lattice structure.

[0152] Twenty-sixth embodiment 20. A method for producing an implant according to any one of claims 1 to 19, comprising: The manufacturing method comprises total additive manufacturing or injection molding of the implant.

[0153] Twenty-seventh embodiment 20. A data structure defining a digital representation of an implant of any of embodiments 1 to 19.

[0154] Twenty-eighth embodiment A computer-readable non-volatile data storage medium storing data defining a digital representation of an implant of any of embodiments 1 to 19.

[0155] Twenty-ninth embodiment A data stream having data defining a digital representation of an implant of any of embodiments 1 to 19, or configured to generate said data.

[0156] Thirty-first embodiment A data structure, data storage medium, or data stream of embodiment 27, embodiment 28, or embodiment 29, wherein the data further includes operating instructions configured to control an additive manufacturing apparatus to manufacture the implant using a digital representation of the implant when the data is sent to the additive manufacturing apparatus. [Explanation of symbols]

[0157] 1. Thorax 3 Bone defects 5-i Ribs 10. System for covering large bone defects 11 Fixation device 70 Data storage media 75 Data that defines digital display 100 Implants 100' Implant 100'' implant 110-i Lattice Cell 120 Ring member 130 Bridge member 140 Lattice Structure 141-i Long strip section 142-i Short strip section 200 Implants 210-i Lattice Cell 240 Lattice Structure 250-i bar unit 300 Implants 311-i Low density lattice cell LDLC 312-i High Density Lattice Cell HDLC 340 Lattice Structure 341-i 1st type strip section 342-i Second type strip section 400 Implants 410-i Lattice Cell 431 Bridge members 432 Bridge members 440-i Lattice structure 450-i bar unit 500 Implants 510-i Lattice Cell 531 S-shaped bridge member 532 Straight bridge member 540-i Lattice structure 550-i bar unit 600 Implants 610-i Lattice Cell 640-i Lattice structure 650 bar unit 700 Implants 710-i Lattice Cell 731 S-shaped bridge member 732 Straight bridge members 740-i Lattice structure 750-i bar unit 800 Implants 810-i Lattice Cell 840-i Lattice structure 850 bar unit 900 Implants 940-i Lattice structure 1000 implants 1050-i Bar Unit 1051-i Through hole pair of the first bar unit 1050-1 1052-i Through hole pair of second bar unit 1050-2 1053-i Pair of through holes in the third bar unit 1050-3 1061-i Column of lattice cells of the first lattice structure 740-1 1062-i Column of lattice cells of second lattice structure 740-2 1100 Implant 1140 Lattice structure 1150 Bar Unit 1151-i Through hole pair LA-i Longitudinal axis S10···S20 Method steps S100···S300 Method steps

Claims

1. An implant for covering a bone defect in the thorax, comprising: at least one lattice structure having a plurality of individual lattice cells; each of the plurality of lattice cells having one or more ring members, the ring members having through holes configured to receive fixation devices; At least some of the ring members in the lattice structure are connected to one another via non-linear bridge members; 4. An implant, characterized in that the implant is made at least primarily of a plastic material.

2. 2. The implant of claim 1, characterized in that it is made from a plastic material using an additive manufacturing method AM and / or injection molding.

3. 2. The implant of claim 1, characterized in that it is made of a material including or consisting of polyetheretherketone, PEEK, polyethylene, PE, polyphenylsulfone, polysulfone, polyetherketoneketone, PEKK, magnesium, molybdenum, and / or composites thereof.

4. 2. The implant according to claim 1, characterized in that it is formed from a material having a composite containing hydroxylapatite, HA, tricalcium phosphate, TCP, silver and / or magnesium and / or a material consisting of said composite.

5. 2. The implant of claim 1, wherein said at least one lattice structure has antibacterial properties.

6. 10. The implant of claim 1, wherein the at least one lattice structure has a thickness of about 0.1 mm to about 0.5 mm.

7. 2. The implant of claim 1, wherein the lattice structure is a substantially two-dimensional lattice, such as a triclinic lattice, a monoclinic lattice, an orthorhombic lattice, a tetragonal lattice, a hexagonal lattice, or a cubic lattice.

8. 10. The implant of claim 1, wherein at least a portion of the lattice cells comprises a single link member along with at least a portion of at least one bridge member.

9. 2. The implant of claim 1, wherein all of the connections between the ring members are non-linear.

10. 2. The implant of claim 1, comprising at least one low density lattice cell LDLC and at least one high density lattice cell HDLC having the same size and shape as the at least one lattice cell LDLC but with more ring members.

11. 10. The implant of claim 1, comprising at least one lattice structure and at least one bar unit, said lattice structure and said bar unit being arranged in a regular pattern.

12. The implant of claim 11 , wherein the lattice structures and the bar units are arranged in an alternating manner.

13. 12. The implant of claim 11, wherein the lattice cells immediately adjacent to a bar unit are connected to the bar unit by linear bridge members.

14. 12. The implant according to claim 11, wherein the bridge members connecting the ring members in a direction parallel to the longitudinal direction of the at least one bar unit are linear bridge members.

15. 12. The implant of claim 11, comprising a plurality of bar units arranged in an offset relationship with respect to one another.

16. 12. The implant of claim 11, comprising a plurality of bar units arranged parallel to one another and precisely aligned with respect to their longitudinal ends.

17. 12. The implant of claim 11, wherein the burr unit has at least one row of through holes for receiving fixation devices.

18. 12. The implant of claim 11, wherein the at least one burr unit has a plurality of through hole pairs, the plurality of through hole pairs being disposed along a longitudinal axis of the burr unit.

19. The implant of claim 18, characterized in that the through holes of the plurality of through hole pairs are arranged parallel to each other in the plurality of through hole pairs, but are neither parallel nor perpendicular to the longitudinal axis of the at least one bar unit.

20. A system for covering large bone defects, comprising:

10. A system comprising the implant of claim 1 and a plurality of fixation devices.

21. 21. The system of claim 20, wherein the fixation device comprises a biodegradable or non-biodegradable metal screw or pin, or an absorbable or non-absorbable polymer pin or screw.

22. 1. A method for covering a bone defect in a thorax, comprising: Providing a system according to embodiment 20; A method of covering, comprising using the fixation device to fix the implant to at least two portions of the patient's bone.

23. 23. The method of claim 22, wherein the at least two portions of bone are part of one or more ribs, the one or more ribs being partially missing.

24. The system comprises the implant of claim 10 having at least one burr unit, 23. The method of claim 22, wherein the implant is secured to at least one rib of the patient by one or more ring members in at least one lattice structure, whereby at least one bar unit substitutes for a missing portion of at least another rib of the patient.

25. 23. The method of claim 22, wherein the implant is tailored to a particular patient and / or a particular bone defect after manufacture by removing a portion of at least one lattice structure.

26. 13. A method for producing the implant of claim 1, comprising the steps of: A manufacturing method comprising additive manufacturing or injection molding of the entire implant.

27. 2. A data structure defining a digital representation of the implant of claim 1.

28. 10. A computer readable non-volatile data storage medium storing data defining a digital representation of the implant of claim 1.

29. 10. A data stream comprising or configured to generate data defining a digital representation of an implant according to claim 1.

30. 30. The data structure of claim 27, the data storage medium of claim 28 or the data stream of claim 29, wherein the data further comprises operational instructions configured to control an additive manufacturing machine to manufacture the implant using a digital representation of the implant when the data is sent to the additive manufacturing machine.

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