Bone Screw Receiver with Additive Porous Layer for Fusion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bone screws used in surgical treatments for spinal disorders lack optimal integration with bone tissue, leading to issues such as reduced stability and compromised fusion due to traditional manufacturing methods.
Innovation Solution
A hybrid manufacturing approach combining traditional and additive manufacturing methods to create a variable structured implant receiver with a porous layer, enhancing bone integration and fusion, while maintaining mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used to create bone screws, then manufacturing precision and mechanical strength are maintained, but bone integration and fusion are compromised due to lack of porous structure
Solution Approach 1:
The patent combines traditional manufacturing methods (CNC machining, turning, milling) with additive manufacturing (3D printing) to create a hybrid bone screw. The receiver portion is additively manufactured with porous structure to enhance bone integration, while the shaft and threading are produced using traditional methods to ensure mechanical strength and precision. This merging of manufacturing approaches resolves the contradiction between achieving good bone integration and maintaining ease of manufacture.
Solution Approach 2:
The receiver of the bone screw is designed with a porous structure created through additive manufacturing. This porous structure allows bone ingrowth and improves biological fixation, directly addressing the bone integration issue. The porous material maintains mechanical integrity while providing pathways for bone cells to penetrate and bond with the implant.
2Reliability
If additive manufacturing is used to create porous structure for bone integration, then bone fusion is enhanced, but mechanical strength and manufacturing precision are reduced
Solution Approach 1:
The bone screw is divided into distinct functional segments: the receiver portion (additively manufactured with porous structure for bone fusion) and the shaft portion (traditionally manufactured with high mechanical strength). This segmentation allows each part to be optimized for its specific function without compromising the other, resolving the contradiction between bone fusion enhancement and mechanical strength maintenance.
Solution Approach 2:
The bone screw employs composite construction by joining materials or structures with different properties - the porous additively manufactured receiver material optimized for bone ingrowth, and the traditionally manufactured shaft material optimized for mechanical strength. The hybrid manufacturing process creates a composite structure that leverages the advantages of both manufacturing approaches.
3Reliability
If hybrid manufacturing is used to create variable structured implant receiver, then bone integration is improved, but device complexity increases
Solution Approach 1:
The additive manufacturing of the receiver is performed as a preliminary action before final assembly with the shaft. The porous receiver structure is pre-formed with embedded features (such as titanium mesh or reinforcement structures) before the traditional manufacturing and assembly steps. This preliminary action simplifies the overall process by preparing the complex porous structure in advance rather than attempting to create it during final assembly.
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 hybrid manufacturing method improves bone screw integration and fusion by promoting bony in-growth and preventing toggle, ensuring stability and effective fixation in spinal constructs.
Implementation Method 1
The porous layer is configured to promote bony in-growth
Implementation Method 2
a porous layer, enhancing bone integration and fusion
Data Source
Figure 1~4
Figure 2~3
Figure 5
AI summary
An implant receiver comprises a body formed by a first manufacturing method, the body including an outer surface and having spaced apart walls defining a cavity configured for disposal of a spinal implant; and at least one layer being formed onto at least a portion of the outer surface by a second manufacturing method. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed.