Cranial Implant with Integrated Fixation Tabs
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Solution Overview
Problem
Current cranial implants face challenges such as the need for pre-plating, potential inaccuracies in contouring to the skull shape leading to deformities, and the use of metallic materials causing artifacts in medical imaging.
Innovation Solution
A cranial implant with integrated fixation tabs, where the tabs include a tab connecting shaft and a tab anchoring end with anchor openings, allowing for customization based on patient-specific skull characteristics and fabrication using bio-compatible materials like Peek-Optima, to ensure optimal fit and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate fixation tabs and plates are used, then the implant can be attached to the skull, but the surgery time increases due to pre-plating requirements
Solution Approach 1:
The patent combines the fixation tab and the skull plate into a single integrated implant component. The fixation tab is directly formed as part of the skull plate structure, eliminating the need for separate pre-plating operations. This integration allows the implant to be attached to the skull in a single step during surgery, significantly reducing surgery time and eliminating the complex pre-plating process.
2Manufacturing precision
If standard flat plates are used, then manufacturing is simplified, but contouring inaccuracies cause skull deformities
Solution Approach 1:
The patent applies local quality by creating a custom-contoured skull plate where only the specific regions requiring contouring are shaped to match the patient's skull anatomy. The fixation tab region maintains its structural integrity while the plate surface is contoured locally to fit the skull's curvature. This approach achieves high contouring accuracy without requiring complete reshaping of the entire plate, balancing manufacturing precision with ease of fabrication.
3Strength
If metallic materials are used for the implant, then structural strength is ensured, but imaging artifacts are created in CT scans and X-rays
Solution Approach 1:
The patent employs composite materials, specifically combining PEEK (polyether ether ketone) polymer with carbon fiber reinforcement. This composite material provides structural strength comparable to metals while being radiolucent, meaning it does not create artifacts in CT scans and X-rays. The carbon fiber-reinforced PEEK achieves the necessary mechanical properties for skull implantation without the imaging interference problems associated with metallic implants.
Data Source
AI summary
A cranial implant and a method for generating and implementing the cranial implant is provided, wherein the cranial implant includes at least one fixation tab. The method includes determining the characteristics of a skull of a patient and an opening in the skull, identifying the desired location of the at least one fixation tab, fabricating the cranial implant based on at least one of a predetermined algorithm and experience of a fabricator in response to at least one of the characteristic of the skull/opening in the skull and the location of the fixation tabs, adjusting the cranial implant to fit within the opening of the skull such the cranial implant is substantially flush with a surface of the skull and securing the cranial implant to the skull using one or more fixation screws.