Adjustable Spacer Mold for Patient-Specific Joint Prostheses

Solution Overview

Problem

Existing molds for forming spacer devices for joint prostheses are cumbersome and require multiple molds to accommodate the varying physical conformation and needs of each patient, leading to inefficiencies and increased costs.

Innovation Solution

An adjustable mold with adjustable height and thickness capabilities, allowing for the formation of spacer devices tailored to individual patient needs using interchangeable inserts and adjustable components, along with a kit containing multiple inserts for varying dimensions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple different molds are used to accommodate varying patient needs, then adaptability to patient-specific requirements is improved, but device complexity and costs increase

Engineering Contradiction:

Improveadaptability to patient-specific requirementsVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mold is designed with adjustable components including a movable plunger and interchangeable inserts that allow a single mold to produce spacer devices of various heights, thicknesses, and geometries. This universal design eliminates the need for multiple specialized molds while maintaining the ability to accommodate varying patient anatomical requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mold incorporates dynamic adjustable elements such as a movable plunger that can be positioned at different heights and interchangeable inserts that can be swapped to change the molding cavity geometry. These dynamic features enable the mold to adapt its configuration for different patient needs without requiring multiple static mold designs

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple different molds are used to accommodate varying patient needs, then adaptability to patient-specific requirements is improved, but costs increase

Engineering Contradiction:

Improveadaptability to patient-specific requirementsVSAvoidcosts

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The mold is designed with adjustable components including a movable plunger and interchangeable inserts that allow a single mold to produce spacer devices of various heights, thicknesses, and geometries. This universal design eliminates the need for multiple specialized molds while maintaining the ability to accommodate varying patient anatomical requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The design allows for the reuse of the main mold body with different interchangeable inserts, thereby recovering and reusing the expensive mold infrastructure while only discarding or replacing the relatively inexpensive inserts, reducing overall manufacturing costs

Inventive Principle:

Principle #34Discarding and recovering

3Ease of manufacture

If traditional molds are used, then manufacturing process is simple, but productivity decreases due to need for multiple molds

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidproductivity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The mold incorporates dynamic adjustable elements such as a movable plunger that can be positioned at different heights and interchangeable inserts that can be swapped to change the molding cavity geometry. These dynamic features enable the mold to adapt its configuration for different patient needs without requiring multiple static mold designs

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mold is divided into separable components including the main body, movable plunger, and interchangeable inserts. This segmentation allows the inserts to be quickly swapped while keeping the main mold structure in place, enabling rapid reconfiguration for different production needs without redesigning the entire molding system

Inventive Principle:

Principle #1Segmentation

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

Enables quick, versatile, and cost-effective production of spacer devices in various sizes, adapting to patient-specific requirements with ease and efficiency.

Implementation Method 1

The material with which spacer devices for replacing a joint prosthesis are usually made is a known material, for example bone cement, which initially appears in the fluid state and which, after a certain period of time, hardens.

Methodology Applied

Scientific EffectPhase change (hardening): Phase Change

Data Source

PatentUS20250331991A1Adjustable mold for forming spacer devices or parts thereof

Publication Date: 2025.10.30 TECRES SPA

AI summary

An adjustable mold for forming spacer devices or parts thereof for the replacement of a joint prosthesis or part thereof, and the related kit for forming such spacer devices or parts thereof.