Build-plate with Integrally-formed Spinal Implant Constructs
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Solution Overview
Problem
Existing methods for manufacturing spinal implants using additive and subtractive processes are inefficient due to the need for individual formation and subsequent refinement, lacking a systematic approach for repeatable and batch processing.
Innovation Solution
A build-plate with specific orienting surfaces is used to facilitate both additive and subtractive manufacturing processes, allowing for the formation and refinement of spinal implants in a coordinated manner, enabling repeatable and batch processing through precise alignment and material removal pathways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spinal implants are formed individually using additive manufacturing processes followed by subtractive manufacturing processes, then the implants can be created with basic shapes and refined geometries, but the manufacturing efficiency is low and batch processing is not achieved
Solution Approach 1:
The patent combines multiple spinal implant constructs into a single integrated build-plate structure, allowing simultaneous additive manufacturing of multiple implants in one batch process. The build-plate serves as a common substrate that holds multiple implant constructs, enabling parallel production and significantly improving manufacturing efficiency while maintaining individual implant geometry requirements
Solution Approach 2:
The build-plate is designed with multiple orienting surfaces that serve dual purposes: (1) providing attachment surfaces for multiple implant constructs during additive manufacturing, and (2) providing alignment references for subsequent subtractive manufacturing processes. This multi-functional design eliminates the need for separate fixtures and setup procedures, reducing process complexity
2Productivity
If multiple spinal implant constructs are formed on a single build-plate using additive manufacturing, then batch processing and volume production are enabled, but precise alignment and orientation for subsequent subtractive manufacturing become more challenging
Solution Approach 1:
The build-plate is pre-configured with multiple orienting surfaces at predetermined locations and orientations before the additive manufacturing process begins. These orienting surfaces are integrated into the build-plate design and provide built-in alignment references that guide the subsequent subtractive manufacturing tools, ensuring precise positioning of each implant construct without requiring complex measurement and adjustment procedures
Solution Approach 2:
The orienting surfaces act as intermediary elements between the additive manufacturing process and the subtractive manufacturing process. These surfaces provide a common reference framework that translates the positions of multiple implant constructs on the build-plate into precise alignment cues for subtractive tools, enabling accurate processing of multiple implants simultaneously
Data Source
AI summary
A build-plate with integrally-formed spinal implant constructs and a method used in forming spinal implant constructs on the build plate and machining the spinal implant constructs formed on the build plate to manufacture spinal implants is provided. The spinal implant constructs can be formed via additive manufacturing processes by adding material to an upper surface of the build plate, and then the spinal implant constructs can be subjected to subtractive manufacturing processes to form the spinal implants.