Custom Acetabular Implant Shaping From Standard Prosthesis Blanks
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Solution Overview
Problem
Current hip revision prostheses require a large inventory of different sizes and types to accommodate varying patient anatomy, leading to increased surgical time, cost, and complexity due to the need for additional mounting points and customization, which is not efficiently addressed by existing technologies.
Innovation Solution
A method involving the analysis of tomography data to create a custom acetabular prosthesis using a custom deforming fixture or press die mold, allowing for precise shaping of pre-manufactured blanks to match individual patient anatomy, reducing the need for multiple prosthetic sizes and inventory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pre-manufactured revision acetabular prostheses with different flange configurations are maintained in inventory to accommodate various patient anatomies, then adaptability to different patient conditions is improved, but device complexity and inventory costs increase
Solution Approach 1:
A single standardized revision acetabular prosthesis design with integral flanges is made universally adaptable through post-manufacturing customization. The flanges can be shaped and contoured during surgery to match various patient anatomies, eliminating the need for multiple pre-configured prosthesis types while maintaining adaptability to different pelvic structures.
Solution Approach 2:
The prosthesis transitions from a static, pre-configured design to a dynamic, customizable form. The flanges are designed to be modifiable during surgery, allowing surgeons to adapt the geometry to match patient-specific anatomy. This dynamic adaptability replaces the need for multiple static variants in inventory.
2Reliability
If surgeons use ilium, pubis, and/or ischium flanges that are shaped during surgery to match patient pelvis anatomy, then reliability of securement is improved, but surgical time and complexity increase
Solution Approach 1:
The flanges are pre-integrated into the prosthesis design and pre-positioned to provide immediate securement capability. Rather than requiring extensive intraoperative shaping and customization, the flanges are ready for attachment to the ilium, pubis, and/or ischium, reducing surgical time while maintaining reliable securement through proper initial positioning and anatomical matching.
3Adaptability or versatility
If a large inventory of different revision acetabular cups is maintained to account for various surgical conditions, then adaptability to unexpected conditions is improved, but hospital costs and inventory control complexity increase
Solution Approach 1:
A single standardized revision acetabular prosthesis design serves multiple surgical conditions through its integral flange configuration. The universal design with modifiable flanges can be adapted during surgery to address various anatomical variations and unexpected conditions, eliminating the need to maintain a large inventory of specialized cup variants.
Solution Approach 2:
The prosthesis maintains adaptability through parameter changes in flange geometry and positioning that can be adjusted during surgery. Rather than requiring different physical prosthesis types for different conditions, the same base design can be modified to suit various surgical scenarios, reducing inventory requirements while maintaining versatility.
Data Source
AI summary
A method of making a custom acetabular implant for a patient. The method comprises acquiring and analyzing tomography data of the patient, and obtaining geometry and measurement parameters of the patient's pelvic anatomy. A standard acetabular prosthesis blank is selected from a plurality of pre-manufactured blanks, and includes a cup portion and at least one flange. The method includes shaping the blank acetabular prosthesis using a custom deforming fixture such that the shaped acetabular prosthesis has a final shaped geometry and measurement parameters to substantially match the patient's pelvic anatomy relative to the patient's acetabulum.