Bone Void Sculpting Instrument for Implant-Matched Cavities

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Solution Overview

Problem

Existing joint arthroplasty methods face challenges in creating a bone void that accurately matches the shape of prosthetic implants, often leading to high mechanical stress and intraoperative fractures, especially in minimally-invasive procedures.

Innovation Solution

A bone void sculpting instrument with a tool frame and interlocked bone sculpting tools that form continuous loops along non-circular paths, allowing for the creation of an irregularly shaped bone void that closely matches the prosthetic implant, using a minimally invasive approach and reducing mechanical stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional bone preparation methods are used, then the bone void can be prepared quickly, but the mechanical stress on the bone is high causing intraoperative fractures

Engineering Contradiction:

Improvereduction of intraoperative fractureVSAvoidpeak mechanical stress

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The bone preparation process is divided into multiple staged reaming operations rather than a single high-stress event. The instrument performs sequential passes to progressively create the bone void, distributing the mechanical stress over time and preventing peak stress fractures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reaming instrument incorporates dynamic control of rotation speed and reaming pressure throughout the bone preparation process. The system adjusts operational parameters in real-time to maintain low peak stresses while effectively preparing the bone void shape

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If minimally-invasive approaches are used, then the surgical access is reduced, but the ability to create accurately shaped bone voids is compromised

Engineering Contradiction:

Improveminimally invasive accessVSAvoidbone void shape accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The instrument creates a three-dimensional bone void shape through controlled reaming motions that extend beyond simple linear access. By utilizing rotational and radial dimensional control, the system achieves precise bone void geometry through minimally invasive entry points

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The bone preparation system incorporates feedback mechanisms to monitor and adjust reaming parameters in real-time. This feedback control ensures accurate bone void shaping while maintaining minimal invasive access by adapting to the patient's anatomy during the procedure

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If the bone void is prepared to match the prosthetic implant shape, then the implant-bone match is improved, but the complexity of the preparation process increases

Engineering Contradiction:

Improveimplant-bone shape matchVSAvoidpreparation process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The reaming instrument is designed with multi-functionality to handle various bone void shapes and implant types through a single versatile tool. The instrument can prepare for different implant geometries by adjusting reaming parameters and tooling configurations, reducing the need for multiple specialized tools

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12446899B2Device, method, and kit for preparing a bone void for joint replacement

Publication Date: 2025.10.21 KARAS GRP LLC

AI summary

Systems and methods for use of an instrument for preparing a bone for joint replacement is provided. In various embodiments, the instrument comprises a tool frame, a drive interface, a drive shaft, at least one torque interface, and a plurality of bone sculpting tools interlocked to form at least one continuous loop. Methods and systems for preparing a femur for total hip arthroplasty are also provided.