Anatomical Model Manufacturing via Composite 3D Printing and Molding
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Solution Overview
Problem
Current 3D printing methods are limited in replicating the elastic strength and deformability of human organs, as they can only use materials with hardness above a certain threshold, failing to accurately simulate the tactile response of organs like the liver or kidney, which is essential for realistic surgical training and planning.
Innovation Solution
A method combining additive printing, molding, and material extrusion, using software libraries to select tissue-equivalent materials and manufacturing techniques based on the anatomical structure's hardness, allowing for the creation of anatomical models that mimic the haptic characteristics of organs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional 3D printing methods are used to manufacture anatomical models, then manufacturing speed and geometric flexibility are improved, but the ability to replicate organ elasticity and deformability deteriorates due to material hardness constraints
Solution Approach 1:
The patent uses composite materials consisting of a rigid support structure (3D printed) combined with soft organ replicas made through molding processes. This allows the model to have both structural integrity for handling and soft, elastic surfaces that accurately replicate organ tactile properties, resolving the contradiction between manufacturing capability and tactile realism.
Solution Approach 2:
The anatomical model is divided into multiple components: a rigid support structure containing internal cavities, and separate soft organ replicas that are molded into these cavities. This segmentation allows each component to be manufactured using optimal processes - 3D printing for the support and molding for the soft organs - thereby achieving both manufacturing efficiency and tactile accuracy.
2Reliability
If soft materials with low hardness are used to simulate organ deformability, then tactile response accuracy is improved, but manufacturing complexity increases due to material handling difficulties
Solution Approach 1:
The rigid support structure with precisely engineered internal cavities is manufactured in advance using 3D printing. This preliminary action creates ready-made molds that simplify the subsequent soft material replication process, reducing overall manufacturing complexity while maintaining tactile accuracy.
Solution Approach 2:
The rigid support structure acts as an intermediary tool - it is easily manufacturable through 3D printing and serves as a mold for creating the soft organ replicas. This intermediary approach simplifies the handling of soft materials by providing a structured framework that guides their formation.
3Reliability
If expensive non-rigid materials are used to achieve organ-like elasticity, then tactile response accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies different material qualities to different parts of the model: expensive soft materials are used only for the organ replicas where tactile accuracy is critical, while the bulk support structure uses cheaper rigid materials. This local differentiation maintains tactile realism where needed while controlling overall manufacturing costs.
Data Source
AI summary
The invention relates to a method for manufacturing anatomical models adapted to simulate organs or parts of organs of a patient. The method includes selecting elements of an anatomical structure of an organ or part of an organ from processed images to obtain a three-dimensional computerized model representing the three-dimensional computerized model by a file having a valid format usable in a three-dimensional printing process; selecting at least one material from a first software library of usable material and at least one manufacturing method from a second software library of manufacturing methods based on a parameter representative of a hardness measurement of said organ; modifying the file representative of the three-dimensional computerized model based on the at least one material and the at least one manufacturing method; using the modified file to perform the process for manufacturing the anatomical model by a three-dimensional printing unit.