Cartilage Implant Mold Using Shape Memory Substrate
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Solution Overview
Problem
Existing methods for repairing tissue defects, such as cartilage defects, often fail to create implants with surface contours that accurately match the three-dimensional shape of the defect, leading to suboptimal repair outcomes.
Innovation Solution
A method involving the formation of a mold conforming to the tissue defect's contours using a pliable substrate with shape memory, followed by the creation of an implant comprising tissue particles and a biocompatible carrier, which is then applied to the defect, ensuring a precise fit and minimally invasive insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional two-dimensional flat sheets or layers are used to repair tissue defects, then the implant is easy to manufacture and apply, but the surface contour does not match the three-dimensional shape of the defect
Solution Approach 1:
The patent transitions from two-dimensional flat sheets to three-dimensional molded implants that conform to the complex geometry of cartilage defects. The molding process creates implants with depth variations and surface contours that match the defect's three-dimensional shape, improving integration and repair outcomes.
Solution Approach 2:
The patent uses the defect's own geometry as a template by creating a mold from the defect surface. This mold is then used to produce implants that are precise copies of the defect's shape, ensuring optimal fit and contact with the surrounding healthy cartilage.
2Reliability
If custom-shaped implants are created to match defect contours, then repair efficacy improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent performs preliminary action by creating a mold from the defect geometry before producing the final implant. This pre-molding step captures the exact shape requirements, allowing subsequent implant fabrication to proceed with standardized molding processes rather than complex custom shaping.
Solution Approach 2:
The patent utilizes parameter changes in the molding process, including temperature control and material phase transitions, to efficiently produce complex-shaped implants. The molding technique allows transformation of material from a pliable state during shaping to a stable final form, simplifying manufacturing of custom geometries.
3Productivity
If the mold is made from impermeable material, then the implant structure is simple, but liquid medium cannot be removed efficiently
Solution Approach 1:
The patent employs porous or permeable mold materials that allow liquid medium to pass through during the molding process. This enables efficient drainage and removal of excess liquid from the implant while the mold maintains its structural integrity and shape-defining properties.
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
This approach allows for the creation of implants that closely match the defect's shape, potentially improving repair efficacy and recovery speed by providing a biocompatible, contour-specific solution for tissue defects.
Implementation Method 1
a pliable substrate having shape memory
Data Source
AI summary
Implants for repairing tissue defects, such as cartilage tissue defects, and methods of their preparation and use are disclosed. A mold of a tissue defect is prepared by pressing upon the defect a substrate having shape memory, such as aluminum foil. The mold, which has contours substantially conforming to those of the defect, is removed from the defect, and tissue particles are added to the mold ex vivo. A biological carrier such as biocompatible glue is also added to the mold. The combination of tissue particles and the biological carrier thereby form an implant, which retains its shape after separation from the mold. The implant can be transferred to the tissue defect, with contours of the mold matching corresponding contours of the defect.