Additive Manufacturing Articulating Interbody Fusion Devices

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Solution Overview

Problem

Traditional manufacturing methods for articulating interbody fusion devices are costly, time-consuming, and limit design flexibility, necessitating the development of alternative manufacturing techniques that simplify the process while maintaining or enhancing design capabilities.

Innovation Solution

The use of additive manufacturing processes to create articulating interbody fusion devices with interconnected pores and a rotatable articulating connector, allowing for the device to be assembled without support structures and featuring a modulus of elasticity similar to bone, with stop surfaces to limit rotational movement, and a porous structure for bone in-growth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional machining processes are used to manufacture articulating interbody fusion devices, then manufacturing precision and structural integrity are maintained, but manufacturing cost increases and design flexibility is limited

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidimplant positioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the manufacturing parameter from traditional subtractive machining to additive manufacturing. This parameter change enables complex geometries with interconnected pores and articulating connectors to be manufactured directly, reducing manufacturing steps while maintaining precision through digital model control. The additive process allows precise control of pore interconnectivity and articulation surfaces without requiring complex machining operations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical machining system with an additive manufacturing system. Instead of removing material through cutting tools, the invention uses layer-by-layer deposition to create the implant. This substitution eliminates the need for complex multi-step machining while achieving the same and improved geometric precision, directly addressing the contradiction between manufacturing simplicity and precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If traditional machining processes are used, then structural integrity is maintained, but manufacturing time increases and design flexibility is reduced

Engineering Contradiction:

Improvemanufacturing cycle timeVSAvoiddesign customization capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent applies preliminary action by creating a digital twin or virtual model of the implant before manufacturing. The additive manufacturing process uses pre-programmed digital data that contains all geometric details, allowing the complex articulating connector and pore structures to be manufactured directly without time-consuming machining operations. This preliminary digital preparation enables both rapid production and customized designs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces dynamics by enabling adjustable parameters in the additive manufacturing process. The digital model allows real-time modification of pore size, distribution, and articulation angles without requiring physical retooling. This dynamic adjustability in the manufacturing process itself provides design flexibility while maintaining consistent manufacturing time, resolving the contradiction between productivity and adaptability.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If complex machining processes are used, then manufacturing precision is maintained, but manufacturing cost increases

Engineering Contradiction:

Improveimplant dimensional accuracyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the implant into functionally distinct regions with different pore densities and articulation characteristics. The additive manufacturing process can independently control the parameters for each segment, achieving precise dimensional control for the articulating surfaces while using simpler processes for less critical areas. This segmentation allows high precision where needed without requiring complex machining throughout the entire structure.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250205060A1Articulating interbody fusion devices and methods of manufacture

Publication Date: 2025.06.26 XENIX MEDICAL LLC

AI summary

An articulating interbody fusion device may include a body including a plurality of interconnected pores, and a recess portion having a first border portion and a second border portion spaced apart from the first border portion. The articulating interbody fusion device may further include an articulating connector configured to be positioned within the recess portion. One of the body and the articulating connector may include an aperture, the other of the body and the articulating connector may include a post positioned within the aperture, the articulating connector may be rotatable relative to the body, and the articulating connector may be irremovable from the body.