3D Printed Bunion Implant with Custom Cutting Guides
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Solution Overview
Problem
Bunions often result in rotational deformity and increased angle between the 1st and 2nd toes, which existing treatments struggle to correct effectively.
Innovation Solution
A bunion correction system involving a pre-designed treatment process, including a 3D-printed implant and kit with custom cutting guides, to realign the metatarsal section of the foot and restore the normal angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bunion correction methods are used, then the treatment process is simpler, but the precision of correcting rotational deformity and reangling the metatarsal is insufficient
Solution Approach 1:
The patent applies preliminary action through pre-operative planning and customization. The implant system is designed and configured before surgery based on patient-specific anatomy and deformity characteristics. The plate and screw positions are predetermined to achieve optimal correction of the metatarsal angle and rotational alignment, allowing the surgeon to execute a pre-planned precise correction rather than making intraoperative decisions that may compromise accuracy.
Solution Approach 2:
The patent incorporates feedback through the use of intraoperative alignment tools and measurement techniques. The system includes features for verifying the metatarsal angle and rotational position during surgery, allowing the surgeon to assess whether the desired correction (typically targeting a 10-degree metatarsal angle) has been achieved and make adjustments if necessary. This closed-loop approach ensures precision while providing real-time information to guide the procedure.
2Manufacturing precision
If custom 3D-printed guides and plates are used, then the correction accuracy is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent applies preliminary action through pre-operative planning and customization. The implant system is designed and configured before surgery based on patient-specific anatomy and deformity characteristics. The plate and screw positions are predetermined to achieve optimal correction of the metatarsal angle and rotational alignment, allowing the surgeon to execute a pre-planned precise correction rather than making intraoperative decisions that may compromise accuracy.
Solution Approach 2:
The patent applies parameter changes by utilizing modern manufacturing technologies such as 3D printing and CNC machining to produce custom implants and guides. These technologies have significantly reduced manufacturing lead times compared to traditional methods, allowing for rapid prototyping and production of patient-specific devices. The digital design process enables quick modifications and iterations, reducing the overall time from planning to implementation while maintaining high precision standards.
3Manufacturing precision
If the implant system includes multiple components (guides, plates, screws, wires), then the functionality and precision are improved, but the ease of operation during surgery decreases
Solution Approach 1:
The patent applies merging by integrating multiple functional components into a coordinated system. The guide rails, alignment tools, plate, and screws work together as a unified assembly that simplifies the surgical workflow. The guide rails incorporate both positioning features and cutting guides, while the plate is designed with pre-drilled holes that align with the guide rail positions, eliminating the need for separate alignment steps and reducing the number of individual components the surgeon must manage independently.
Solution Approach 2:
The patent applies segmentation by dividing the surgical procedure into distinct, manageable stages with dedicated components for each stage. The system separates the guidance function (guide rails and alignment tools) from the fixation function (plate and screws), allowing the surgeon to first establish precise alignment and then secure the correction. This modular approach makes the complex procedure more manageable by breaking it down into sequential, well-defined steps rather than requiring simultaneous coordination of all components.
Data Source
AI summary
There is a process for correcting a bone injury, an implant for correcting the bone injury and a kit for applying the implant for correcting the bone injury. The process can be made substantially uniform with the application of a standardized kit. In at least one application the process is for correcting a bunion on a patient. The process can include applying a first drill guide to a bone, and then a second drill guide. Once the drill guides have been applied and wires have been inserted into a bone, an implant can then be applied to correct a bone injury and to allow the bone injury to heal.