3D-Printed Mesh Bone Grafts for Site-Conforming Repair
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Solution Overview
Problem
Traditional 3-D printing methods do not allow for the production of custom-made bone grafts with controlled osteoconductive, osteoinductive, and/or osteogenic properties that can be tailored to specific bone graft sites, lacking the ability to conform to the site and provide desired biological and mechanical properties.
Innovation Solution
A computer-implemented method using a 3-D printing device to fabricate a covered mesh bag with a biocompatible material, which includes a 3-D digital model of the bone graft site, aligning a printing surface and print head, depositing material, rotating to create a mesh pattern, solidifying, and enclosing bone material within a compartment, allowing for customized bone grafts with bioactive agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional 3-D printing methods are used to create bone grafts, then the manufacturing process is simple and straightforward, but the bone grafts cannot be customized to conform to specific bone graft sites and lack controlled biological properties
Solution Approach 1:
A 3-D digital model of the bone graft site is obtained and processed in advance to generate fabrication instructions before the actual 3-D printing process. This preliminary digital preparation enables customization to the specific site geometry while keeping the physical manufacturing process relatively simple.
Solution Approach 2:
The system controls the composition, concentration, and distribution of bone material and bioactive agents within the carrier material during 3-D printing. By varying these parameters, the bone graft can be customized to provide specific osteoconductive, osteoinductive, and osteogenic properties tailored to the bone graft site requirements.
2Shape
If monolithic or particulated bone grafts in carriers are used, then the manufacturing process is straightforward, but the implants are substantially solid and do not conform to the implant site
Solution Approach 1:
The 3-D printing process deposits material in successive layers that can be selectively placed and shaped to match the specific geometry of the implant site. This allows different regions of the bone graft to have different shapes and properties, enabling conformity to the implant site while maintaining manufacturing feasibility through automated layer-by-layer construction.
3Adaptability or versatility
If allograft bone is used as a bone graft substitute, then availability is improved and donor site morbidity is avoided, but the ability to customize the graft to specific site requirements is limited
Solution Approach 1:
The system combines carrier material with bone material and bioactive agents in a composite structure. The carrier material provides the structural framework, while bone material and controlled amounts of bioactive agents are integrated to provide osteoinductive and osteogenic properties. This composite approach enables customization of both the physical shape and biological properties to match specific site requirements.
4Shape
If traditional 3-D printing deposits material layer by layer on a flat platform, then the process is simple to implement, but continuous extrusion to create complex three-dimensional objects is not allowed
Solution Approach 1:
The system transitions from traditional two-dimensional layer-by-layer deposition on a flat platform to three-dimensional continuous extrusion. By enabling material to be extruded continuously in three dimensions, the system can create complex spatial structures and hollow regions that conform to the bone graft site geometry, moving beyond the limitations of flat-layer construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of customized bone grafts that conform to the intended bone graft site, providing osteoconductive, osteoinductive, and osteogenic properties, enhancing bone repair by allowing controlled release of bioactive agents and improving integration with the host bone.
Implementation Method 1
Three-dimensional (3-D) printing is an additive printing process used to make three-dimensional solid objects from a digital model. 3-D printing techniques are considered additive processes because they involve the application of successive layers of material.
Implementation Method 2
3-D printing does not allow for continuous extrusion to create an object. However, the present disclosure provides a system and method of producing custom bone grafts that can be used as ink in a 3-D printer to produce bone grafts of any desired shape.
Data Source
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AI summary
A computer implemented method of fabricating a mesh bag (70) for a mesh implant through use of a 3-D printing device (10). The method comprising: a step for inputting instructions for a computer processor (102) to carry out the fabrication; a step (220) for aligning a printing surface (12), a base (16) and a print head (30) relative to one another; a step (230) for depositing material (40) onto the printing surface (12); a step (240) for rotating the printing surface (12) and moving the base (16) to create a mesh pattern; a step (250) for solidifying the material (40) on the printing surface (12); a step (251) for 3-D printing of the mesh bag (70) having a compartment (81) that is accessible through an opening; a step (252) for filling the compartment (81) with bone material; a step (253) for enclosing mesh bag (70) by 3-D printing a covering for enclosing the bone material within the compartment (81) of the mesh bag (70); and a and step (260) for removing the 3-D formed and covered mesh bag (70). A mesh implant comprising a mesh bag (70) including a compartment (81) filled with bone material prepared by the computer implemented method is also provided.