Ceramic Imprint Moulding for Articular Prosthesis
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Solution Overview
Problem
The existing methods for manufacturing articular prosthesis implants using thermoplastic materials face challenges with high adhesion to metal moulds, leading to difficult extraction and potential mechanical property issues, and require the use of costly release agents to facilitate removal.
Innovation Solution
A method involving heating thermoplastic materials to malleability and using a ceramic imprint within a mould cavity, pressed by a piston, to form the implant without the need for release agents, allowing for safe and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal mould cavity is used to mould thermoplastic material, then the implant can be formed with good shape, but the adhesion between thermoplastic material and metal cavity is extremely high making extraction extremely difficult
Solution Approach 1:
A ceramic imprint is introduced as an intermediary element between the metal mould cavity and the thermoplastic material. The ceramic imprint contacts the thermoplastic material directly, allowing it to take the shape of the imprint while the metal cavity only provides structural support. This intermediary ceramic layer prevents direct adhesion between the thermoplastic material and metal cavity, enabling easy extraction without compromising shape accuracy.
Solution Approach 2:
The ceramic imprint serves as a copy or replica of the desired implant shape within the mould cavity. Instead of directly moulding the thermoplastic material against the metal cavity walls, the ceramic imprint replicates the target geometry, allowing the thermoplastic material to conform to the ceramic shape while avoiding direct contact with the metal cavity surfaces.
2Ease of manufacture
If a release agent is applied to the mould cavity to facilitate implant extraction, then extraction becomes easier and safer, but the manufacturing duration increases and manufacturing cost increases
Solution Approach 1:
The ceramic imprint acts as a disposable or reusable intermediary element that is inexpensive compared to the complexity of release agent systems. The ceramic imprint can be easily removed or replaced after use, eliminating the need for expensive release agents and their associated application steps, thereby reducing both time and cost while maintaining extraction ease.
Solution Approach 2:
The harmful adhesion problem is extracted from the system by introducing the ceramic imprint as a separate intermediary layer. The ceramic imprint absorbs the interaction between the thermoplastic material and metal cavity, allowing clean extraction without requiring additional release agents. This extraction of the adhesion problem resolves the contradiction by eliminating the need for time-consuming release agent application.
3Ease of manufacture
If a release agent is applied to the mould cavity, then extraction is facilitated, but the manufacturing cost increases due to the expensive release agent component
Solution Approach 1:
The ceramic imprint is a relatively simple, inexpensive component compared to the complex release agent systems. The ceramic imprint can be manufactured cost-effectively and reused or discarded easily, eliminating the need for expensive release agents. This substitution directly reduces manufacturing cost while maintaining the ability to extract implants safely and easily.
Solution Approach 2:
The ceramic imprint serves as a simple intermediary that mediates between the metal cavity and thermoplastic material, providing extraction ease without requiring expensive chemical release agents. The ceramic imprint's simplicity and ease of manufacture make it a cost-effective solution that resolves the contradiction between extraction ease and manufacturing cost.
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 enables fast, safe, and cost-effective production of high-quality articular prosthesis implants by eliminating the need for release agents and ensuring accurate dimensions and mechanical properties.
Implementation Method 1
heating to a malleability temperature a thermoplastic material used to form at least partially the implant
Implementation Method 2
pressing the thermoplastic material so that this material flows inside the mould cavity and takes the shape of the imprint
Implementation Method 3
allowing the thermoplastic material to cool down
Data Source
AI summary
The invention relates to a method and a device for manufacturing an articular prosthesis implant using a mould comprising a ceramic imprint (1) moved by a piston (2), the ceramic imprint (1) pressing the thermoplastic material introduced into the mould.