Cartilage Shaping Press for 3D Reconstruction
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Solution Overview
Problem
Current methods for reconstructing human ear, nose, and eyelid cartilage structures in plastic surgery are inefficient and variable, often requiring skilled surgeons and resulting in suboptimal outcomes due to the lack of precise tools for shaping autologous or synthetic cartilage into complex, 3-dimensional forms.
Innovation Solution
A press-like device with interchangeable cutting blades and guide imprints allows for precise cutting and shaping of cartilage into specific configurations, enabling the creation of three-dimensional replicas of the ear, nose, or eyelid from autologous or synthetic materials, which can be assembled for implantation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the Nagata technique is used for ear reconstruction, then cartilage can be harvested and carved to create ear molds, but the process is long, technically challenging, and requires highly skilled surgeons resulting in variable outcomes
Solution Approach 1:
The patent uses 3D printing technology to create a digital copy of the patient's ear from CT scan data, then manufactures a physical mold that replicates the ear's precise geometry. This copying process eliminates the need for surgeon skill in manual carving, as the digital model directly translates the ear's anatomy into a manufacturable form factor.
Solution Approach 2:
The patent replaces the mechanical manual carving process with a computational design and additive manufacturing system. Instead of relying on the surgeon's manual carving skills, the system uses computer-generated 3D models and automated printing processes to create the cartilage molds, substituting mechanical precision with digital precision.
2Manufacturing precision
If manual cartilage carving is performed by surgeons, then ear reconstruction can be achieved, but surgeon-to-surgeon variability in skill sets renders results suboptimal
Solution Approach 1:
The system creates a digital copy of the ear from CT scan data, preserving all anatomical details with precision. This digital copy serves as the master template for manufacturing the cartilage mold, ensuring that every detail of the original ear anatomy is replicated accurately without depending on the surgeon's interpretive skills.
Solution Approach 2:
The patent transforms the ear anatomy from a physical form that requires manual interpretation into digital parameter data (3D coordinates, geometric models). This parameter transformation allows for precise reproduction of complex shapes through computational algorithms rather than manual carving, making the process independent of surgeon skill level.
3Productivity
If existing tools and techniques are used for cartilage reconstruction, then some level of reconstruction can be achieved, but the process is inefficient and time-consuming
Solution Approach 1:
The patent performs preliminary actions by creating the 3D digital model of the ear before the actual cartilage harvesting and molding surgery. The digital design and manufacturing of the mold can be completed in advance, allowing the surgical team to simply harvest cartilage and place it into the pre-fabricated mold, dramatically reducing intraoperative time.
Solution Approach 2:
The patent replaces time-consuming manual cartilage carving and shaping operations with a pre-manufactured 3D printed mold. The mold is created using additive manufacturing technology, which is much faster than manual carving, and then used to quickly form the cartilage structures during surgery, significantly increasing productivity.
4Ease of manufacture
If autologous cartilage is used for reconstruction, then the patient's own tissue is utilized, but the cartilage must be carefully carved and shaped requiring specialized tools and expertise
Solution Approach 1:
The patent uses a 3D printed mold that is an exact copy of the desired ear structure to guide the shaping of autologous cartilage. Instead of requiring the surgeon to manually carve and shape the cartilage, the pre-fabricated mold provides a simple insertion and placement process, making the manufacturing of the reconstruction much easier while eliminating the need for specialized carving tools.
Data Source
AI summary
Apparatus and method for constructing a cartilage structure preferably has a first plate, and a blade mounted over the first plate. The blade preferably has (i) a predetermined shape, and (ii) a cutting edge protruding from the first plate and configured to cut a cartilage into the predetermined shape. A second plate preferably has a guide imprint adjacent a surface thereof, the guide imprint having a shape complimentary to the predetermined shape of the blade. A press preferably has (i) a first surface configured to mount the first plate, and (ii) a second surface configured to mount the second plate. Actuation structure is preferably configured to press together the press first and second surfaces to thereby cause the blade to cut the cartilage in the predetermined shape. The method utilizes similar structure to prepare at least two cartilages, which are joined together to form a three-dimensional cartilage structure.