Bone Augment with Metallic Liner for Intraoperative Shaping

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Solution Overview

Problem

Existing bone implants or augments are often rigid and cannot be fully remodeled into bone or modified intraoperatively to match the specific shape and size of a bone defect, limiting their effectiveness in repairing damaged bone.

Innovation Solution

A bone augment comprising a porous body with a metallic liner that can be intraoperatively shaped to fit a bone defect, where the metallic liner is injection molded within the porous body to provide a secure mechanical connection and facilitate bone ingrowth, allowing the augment to be remodeled into bone over time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If bone implants are made from metal with permanent shape and size, then manufacturing precision and structural stability are improved, but adaptability to match specific bone defect shapes and complete remodeling capability deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability to bone defect shape

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The bone augment is divided into two distinct segments: a porous body made of resorbable material that can be shaped intraoperatively to match the bone defect, and a metallic liner that provides structural stability and permanent shape. This segmentation allows each component to fulfill its specific function independently while working together as a unified implant system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining resorbable material (such as polymer or ceramic) for the porous body with metal material for the liner. This composite approach integrates the benefits of both materials: the resorbable material enables complete remodeling and intraoperative shaping, while the metal liner provides mechanical strength and permanent form, creating a hybrid implant that achieves both adaptability and stability.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If bone augments are made with permanent shape and size, then manufacturing precision is improved, but ease of intraoperative modification and complete remodeling capability deteriorate

Engineering Contradiction:

Improvepermanent shapeVSAvoidintraoperative modification

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

The porous body is designed to be dynamically adaptable during the healing process. It can be intraoperatively shaped to fit the bone defect and will continue to remodel and integrate with the surrounding bone over time. The metallic liner maintains its permanent shape throughout, providing a stable foundation while the porous body dynamically adapts to the specific anatomical requirements.

Inventive Principle:

Principle #15Dynamics

3Strength

If bone augments are made from metal only, then strength and durability are improved, but ability to be remodeled into bone over time deteriorates

Engineering Contradiction:

Improvemechanical strengthVSAvoidremodeling duration

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

Different regions of the implant have different material properties optimized for their specific functions. The porous body is made of resorbable material with properties suited for bone ingrowth and remodeling, while the metallic liner is made of metal with properties optimized for mechanical strength and structural support. This local differentiation of material quality allows the implant to simultaneously achieve durability and complete remodeling capability.

Inventive Principle:

Principle #3Local quality

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 solution enables a customizable and durable bone repair that integrates with the surrounding bone, enhancing mechanical strength and supporting implants while allowing for complete remodeling, thus providing effective restoration of bone stock.

Implementation Method 1

The metallic liner is injection molded within the bore such that portions of the liner interlock with pores of the porous body

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS9289299B2Method and apparatus for augumenting bone defects

Publication Date: 2016.03.22 BIOMET MFG LLC

AI summary

A bone augment for repairing a bone defect and associated method. The bone augment includes a porous body and a reinforcement member. The porous body defines a plurality of pores and is configured to be intraoperatively shaped to correspond to the bone defect. The reinforcement member is mounted on an exterior surface of the porous body and is configured to be intraoperatively shaped to correspond to the bone defect.