Intraoperative Bone Screw Cutting System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Orthopedic surgical procedures require a large inventory of bone screws of various sizes and lengths, which are typically sterilized in advance, leading to logistical burdens and inefficiencies in preparing for surgeries.
Innovation Solution
A system and method for cutting bone screw blanks to specified lengths and forming self-tapping end portions intraoperatively using a cutting assembly with position adjustment and deburring capabilities, reducing the need for pre-sterilized inventory and enhancing surgical efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple pre-sterilized bone screws of various sizes and lengths are prepared in advance, then surgical options and reliability are improved, but inventory complexity and preparation time increase significantly
Solution Approach 1:
The bone screw blank is designed as a universal component that can be cut to multiple different lengths and configured with different end portions (self-tapping or non-self-tapping) using the same blank type. This multi-functionality allows a single inventory of standardized blanks to replace the need for maintaining separate inventories of numerous pre-configured screw variants, thereby reducing inventory complexity while preserving surgical reliability through intraoperative customization.
Solution Approach 2:
The invention transforms the static, pre-determined screw configuration into a dynamic, intraoperatively adjustable system. The cutting apparatus enables the surgical team to determine the final screw length and end portion configuration based on actual bone anatomy and surgical requirements discovered during the procedure, rather than relying on pre-selected fixed configurations. This dynamic adaptation maintains reliability while reducing the need for extensive pre-inventory preparation.
2Adaptability or versatility
If extensive inventory of bone screws is sterilized and prepared before surgery, then surgical options are improved, but preparation time and loss of time increase
Solution Approach 1:
The bone screw blanks are pre-manufactured, pre-sterilized, and pre-packaged in a standardized form ready for surgical use. This preliminary preparation of the blank inventory eliminates the need for last-minute assembly, configuration, or sterilization of individual screws. During surgery, the blanks are simply cut to required lengths and configured as needed, significantly reducing intraoperative preparation time while maintaining full surgical versatility through the ability to create various screw types from the same blank inventory.
3Adaptability or versatility
If multiple bone screw sizes and configurations are sourced and sterilized, then surgical adaptability is improved, but productivity and efficiency decrease due to restocking and inventory management
Solution Approach 1:
The standardized bone screw blank serves as a universal starting point that can be transformed into multiple different screw configurations (different lengths, self-tapping or non-self-tapping end portions) using the same inventory item. This universality eliminates the need to source, sterilize, and manage separate inventories of numerous screw variants, thereby improving surgical efficiency and productivity by reducing inventory management burden while preserving full surgical adaptability through intraoperative customization.
4Quantity of substance
If bone screws are cut to specified lengths intraoperatively, then inventory requirements are reduced, but manufacturing precision and measurement accuracy become more critical
Solution Approach 1:
The invention replaces manual measurement and cutting methods with a specialized cutting apparatus that integrates measurement and cutting functions. The apparatus includes measurement features that guide the cutting process to achieve precise lengths, reducing reliance on manual measurement skills and minimizing human error. This mechanical system ensures consistent, accurate cuts while simplifying the overall process, thereby maintaining high manufacturing precision even as inventory requirements are reduced through intraoperative cutting.
Data Source
AI summary
A bone screw cutting system can include a cutting assembly having a plurality of blades. The system can further include a position adjustment assembly coupled to the cutting assembly and configured to receive a bone screw blank and position the bone screw blank relative to the cutting assembly. The cutting assembly is configured to cut a bone screw blank received by the position adjustment assembly and to form a self-tapping end portion at a cut end of a resulting cut bone screw.