Disposable Acetabular Reamer From Flat Metal Stock
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Solution Overview
Problem
Existing bone cutting tools, such as acetabular reamers, are difficult to manufacture at low cost and often suffer from deformation and high costs due to complex machinery requirements, making them expensive and not suitable for single-use disposable solutions.
Innovation Solution
A disposable reamer assembly comprising a circular base and a press-formed, thin-walled cutting body made from flat metal stock with appendages, allowing for improved die forming and minimizing stress-induced deformation, enabling accurate hemispherical shape formation and easy disassembly for partial disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If acetabular reamers are press-formed from flat metal stock using complex machinery to minimize warpage and achieve accurate hemispherical form, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The flat metal stock is pre-stamped with a pattern of holes and slits before forming. This preliminary action creates a compliant structure that allows the material to form into an accurate hemispherical shape during press-forming without requiring complex machinery, thereby resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The invention changes the structural parameters of the metal stock by creating a pattern of holes and slits, transforming the rigid flat stock into a compliant structure that can be easily formed into accurate hemispherical shapes using simple press-forming equipment
2Manufacturing precision
If acetabular reamers are made with complex machinery to obtain accurate results with minimum warpage, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The flat metal stock is pre-stamped with holes and slits before forming, which allows the material to be formed into accurate hemispherical shapes with minimum warpage using simple, inexpensive press-forming equipment rather than complex machinery
Solution Approach 2:
The invention creates a disposable reamer that can be manufactured at low cost using simple processes, making it economically viable to discard after single use rather than reusing expensive precision tools
3Reliability
If reamers are designed for single use to prevent cross contamination, then reliability is improved, but ease of manufacture worsens due to need for low-cost disposable design
Solution Approach 1:
The reamer is designed as a disposable tool that can be manufactured at low cost from flat metal stock using simple stamping and press-forming processes, enabling single-use disposal to prevent cross contamination while maintaining ease of manufacture
Solution Approach 2:
The reamer design separates the cutting body from the handle, allowing the cutting body to be a simple, cheap, disposable component that can be easily manufactured and discarded, while the handle can be reused
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
The solution provides a cost-effective, accurate, and disposable bone cutting tool that minimizes deformation and manufacturing complexity, reducing costs and ensuring effective cutting performance while ensuring safety and hygiene through single-use capability.
Implementation Method 1
press-formed, thin-walled, perforated cutting body of flat metal stock
Data Source
AI summary
A disposable reamer is provided, made up of a base and a thin-walled, perforated cutting body of flat metal stock affixed thereto. The base and body may be molded together or assembled together in a mechanical manner. The body is optionally formed so as to comprise a plurality of appendages connected at a center so as to improve die forming of the body into a final desired shape while at the same time minimizing stress-induced deformation in the body.