Adjustable Craniofacial Implants with Self-Aligning Onlays
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Solution Overview
Problem
Current craniofacial implant systems face challenges due to limited selection options, requiring extensive surgical access and customization, leading to inefficient and imprecise placement, especially on complex three-dimensional facial structures, and often result in unpredictable outcomes and surgical failures.
Innovation Solution
The development of craniofacial implants with adjustable components, such as base and onlay components, and surgical instruments like pivoting jaws and positioning forceps, which allow for customizable projection, precise positioning, and stable attachment to the bone, reducing the need for extensive inventory and minimizing surgical exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple implant sizes and shapes are provided to cover all clinical needs, then the selection flexibility is improved, but the inventory complexity and surgical time increase
Solution Approach 1:
The implant is divided into a base implant and a separate onlay component that can be selectively added. The base implant provides the foundational structure, while the onlay component allows for incremental size adjustment without requiring multiple complete implant variants in inventory.
Solution Approach 2:
The implant system transitions from fixed-size pre-manufactured implants to a dynamic, adjustable configuration where the onlay component can be added or removed based on intraoperative measurements and patient anatomy, enabling customization without maintaining extensive inventory.
2Productivity
If standard implants are used without customization, then the surgical procedure is simplified, but the precision and optimality of fit decrease
Solution Approach 1:
The base implant is pre-manufactured with standardized dimensions and the onlay component is prepared in advance with registration features. During surgery, these pre-prepared components are assembled together to achieve precise customization without requiring time-consuming intraoperative carving or shaping.
Solution Approach 2:
The onlay component serves as an intermediary element between the standardized base implant and the patient's unique anatomy. It provides the necessary customization interface that bridges the gap between mass-produced implants and individual patient requirements.
3Object-affected harmful factors
If remote access incisions are used to avoid visible scarring, then the cosmetic outcome is improved, but the precision of implant positioning decreases
Solution Approach 1:
The implant components include self-aligning registration features such as flanges, ledges, and contoured surfaces that automatically guide correct positioning when the implant is inserted through remote access incisions. The implant essentially positions itself using these built-in alignment mechanisms, eliminating the need for direct visual exposure for precise placement.
Data Source
AI summary
Various embodiments of craniofacial implants, surgical instruments, and techniques are described to provide improved surgical results.