3D-Printed Acetabular Shell With Patient-Specific Augment Fixation
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Solution Overview
Problem
Standard manufacturing techniques for monoblock acetabular prosthetic components do not allow for fixation guides, leading to potential dislocation and reduced range of motion in prosthetic hip joints, while constrained designs compromise on mobility.
Innovation Solution
A 3D-printed monoblock acetabular shell component with a porous structure and patient-specific adjuncts, featuring apertures for fixation and customizable geometry, is manufactured using additive processes, allowing for secure attachment and improved range of motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard manufacturing techniques are used for monoblock acetabular components, then manufacturing simplicity is maintained, but fixation guides cannot be incorporated leading to dislocation risk
Solution Approach 1:
The patent employs a porous lattice structure within the monoblock acetabular component that enables the integration of fixation guides and bone ingrowth features. The porous material allows for the incorporation of through-holes and channels that would be difficult to create with standard manufacturing, while maintaining structural integrity and enabling bone integration for improved fixation and stability.
2Reliability
If constrained hip joint designs are used, then dislocation risk is reduced, but range of motion is compromised
Solution Approach 1:
The patent applies local quality by providing constraint features only where needed - specifically through strategically positioned fixation guides and bone ingrowth regions in the porous structure. This localized approach provides dislocation prevention at critical areas while maintaining unrestricted range of motion in the functional joint areas, avoiding the comprehensive constraints of traditional constrained designs.
3Adaptability or versatility
If customization is implemented for patient-specific anatomy, then implant fit is improved, but manufacturing complexity increases
Solution Approach 1:
The porous lattice structure serves multiple functions simultaneously: it provides patient-specific customization through customizable unit cell geometry, enables bone ingrowth for fixation, incorporates fixation guides for stability, and maintains structural strength. This multi-functionality within a single manufacturable structure achieves patient-specific fit without proportionally increasing manufacturing complexity.
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 enhances fixation and reduces dislocation risk by accommodating larger femoral head components and supporting bone ingrowth, while maintaining or improving joint mobility.
Implementation Method 1
a porous outer layer (16) and a porous inner layer (14)
Data Source
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AI summary
An acetabular shell component includes a solid substrate (12), a porous outer layer (16) coupled to the solid substrate, a porous inner layer (14) coupled to the solid substrate, and an inner bearing (18) coupled to the porous inner layer. One or more adjuncts (40) extend outward from the porous outer layer. Each adjunct includes an outer surface that defines a customized patient-specific negative contour shaped to conform to a positive contour of a patient's bone. A method for manufacturing the acetabular shell component using an additive manufacturing process is also disclosed.