Anatomical Model Manufacturing via Segmented Molding and Composite Pouring
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Solution Overview
Problem
Current methods for manufacturing anatomical models using 3D printing face limitations in replicating the texture, resistance, and transparency of soft organs, and fail to effectively position internal elements within the models, leading to suboptimal realism and practicality for surgical simulation and training.
Innovation Solution
A process involving image capture and processing, followed by computer modeling to generate main and internal molds, positioning internal elements using auxiliary rods, and integrating them with a pouring process using parenchyma and filling materials, allowing for realistic reproduction of anatomical structures, including soft tissues and internal elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If direct 3D printing of soft organs is used, then anatomical models can be produced, but the texture, resistance, and transparency are not accurately replicated
Solution Approach 1:
The manufacturing process is divided into multiple stages: creating molds from 3D scans, preparing separate parenchyma and filling materials, and assembling them in layers. This segmentation allows each material to be optimized for its specific properties (transparency, texture, resistance) while maintaining ease of manufacture through standardized procedures.
Solution Approach 2:
The patent uses composite materials consisting of parenchyma material for the outer tissue layers and filling material for internal structures. This combination enables accurate replication of different tissue properties - the parenchyma provides transparency and soft tissue texture, while the filling material provides structural support and internal organ representation.
2Manufacturing precision
If internal elements are positioned in anatomical models, then realism is improved, but the positioning accuracy and integration with external elements is insufficient
Solution Approach 1:
Molds are created in advance with pre-defined cavities and positioning features that guide the placement of internal elements. The 3D scanning and modeling process identifies optimal positions for internal structures before manufacturing begins, ensuring accurate positioning without complex assembly procedures.
Solution Approach 2:
Internal elements are positioned within nested cavities in the parenchyma material. The molding process creates hierarchical nesting where internal organs are placed within their anatomical contexts, with each layer of tissue containing the next, replicating the natural nested structure of biological organs.
3Manufacturing precision
If different materials are used for parenchyma and filling, then texture and resistance are improved, but material cost and processing complexity increase
Solution Approach 1:
Different materials with specific properties are used in different locations: transparent or translucent parenchyma material for outer tissue layers that require visual inspection, and opaque filling material for internal structures where structural support is prioritized. This local differentiation achieves anatomical accuracy without uniformly increasing complexity across the entire model.
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
The process achieves anatomical models that accurately represent the shape, size, texture, and resistance of biological structures, enhancing realism and usability for diagnosis, surgery simulation, and teaching, while improving demolding and material efficiency.
Implementation Method 1
capturing one or more diagnostic images of a structure to be reproduced, for example using CT, MRI or ultrasound techniques
Implementation Method 2
capturing one or more diagnostic images of a structure to be reproduced, for example using CT, MRI or ultrasound techniques
Implementation Method 3
pouring the filling material and, if appropriate, the parenchyma into the molds
Implementation Method 4
The process may comprise a step for applying a vacuum to the molds
Data Source
AI summary
PROCESS FOR THE MANUFACTURE OF ANATOMICAL MODELS which from images obtained and the creation of editable and printable files comprises a sub-process for generating main moulds, a sub-process for generating internal elements, a sub-process for positioning the internal elements which when these include soft elements comprises a step of reversible stiffening, a sub-process for integrating the internal elements comprising a step of pouring of parenchyma and an demoulding step and a post-processing sub-process.