Adjustable Cranial Implant Molding Device
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Solution Overview
Problem
Pre-formed cranial implants often fail to accommodate variations in cranial bone thickness, leading to implants that are either too thick or too thin, and may have differing thicknesses on opposing sides, requiring significant post-curing shaping.
Innovation Solution
A cranial implant molding device with adjustable mold plates that allow for varying thicknesses by using threaded mechanical fasteners and compressible members to adjust the separation distance between mold plates, enabling the production of implants with equal or differing thicknesses on opposing sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-formed cranial implants are used, then the implant can be manufactured in advance, but the implant thickness does not match the variations in cranial bone thickness
Solution Approach 1:
The molding device incorporates adjustable mold plates that can be dynamically positioned at different separation distances. This dynamic adjustment capability allows the same molding device to produce implants with varying thicknesses to match different cranial bone configurations, resolving the contradiction between standardized manufacturing and customized fit requirements
Solution Approach 2:
The device enables parameter changes in implant thickness by adjusting the separation distance between mold plates. This parameter adjustment mechanism allows the molding device to adapt to different cranial bone thickness variations while maintaining the pre-formed manufacturing advantage
2Ease of manufacture
If pre-formed cranial implants are used, then the implant can be manufactured in advance, but significant post-curing shaping is required
Solution Approach 1:
The adjustable mold plates enable preliminary action by allowing the implant to be molded with the correct thickness and configuration during the initial forming process. This eliminates or reduces the need for subsequent post-curing shaping operations, saving time while maintaining pre-formed manufacturing benefits
3Device complexity
If fixed thickness mold plates are used, then the manufacturing process is simple, but the implant cannot accommodate varying thickness requirements
Solution Approach 1:
The mold plates transition from fixed to dynamic/adjustable positions, enabling the same molding device to accommodate varying implant thickness requirements. This dynamic capability provides adaptability while maintaining relative structural simplicity through the use of adjustable rather than completely redesignable plate systems
Data Source
AI summary
A cranial implant molding device having a frame or base that receives a bottom or convex molding plate and a top or concave molding plate in a manner whereby the two plates are separated a distance to receive a settable or curable implant forming material therebetween. The plates are separated by a compressible member such that by the use of threaded mechanical fasteners or similar members the distance between the two plates can be adjusted by tightening or loosening the mechanical members. The thickness of the implant is varied by varying the separation distance on different sides of the frame.