Custom 3D Implant Fabrication via On-Site Additive Manufacturing
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Solution Overview
Problem
Current methods for generating surgical implants are generic, expensive, and time-consuming, often requiring radiation and off-site fabrication, failing to account for individual asymmetries and not allowing for real-time visualization of surgical outcomes or customization with virtual 3D external photographs.
Innovation Solution
A method involving 3D imaging to simulate volumetric changes, generate virtual implants, and fabricate custom implants on-site using 3D printers or CNC machines, allowing for real-time adjustments and biocompatible materials, enabling bespoke customization within hours and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If generic pre-fabricated implants are used, then manufacturing cost and time are reduced, but customization to individual patient anatomy is compromised
Solution Approach 1:
The system performs preliminary 3D scanning and virtual implant design before actual surgery. The implant is designed and fabricated in advance based on patient-specific anatomy obtained through 3D imaging, allowing customization without delaying the surgical procedure.
Solution Approach 2:
The system creates a digital 3D copy of the patient's anatomy through scanning, then uses this digital model to design and fabricate a custom implant that precisely matches the patient's unique anatomical features, replacing generic implants with personalized ones.
2Manufacturing precision
If custom implants are fabricated off-site at laboratories, then customization precision is improved, but turnaround time increases to several days or weeks
Solution Approach 1:
The system replaces traditional off-site laboratory fabrication with on-site additive manufacturing (3D printing). This substitution of manufacturing method enables precise custom implants to be produced rapidly in the operating room or nearby facility, eliminating the weeks-long turnaround of external laboratories.
Solution Approach 2:
The system performs preliminary design and preparation of custom implants using on-site 3D printing technology, allowing the implant to be ready before surgery without requiring extended off-site fabrication time.
3Measurement precision
If CT scans are used for 3D imaging, then anatomical data accuracy is improved, but patient radiation exposure and cost increase
Solution Approach 1:
The system creates a 3D surface copy of the patient's anatomy using optical scanning or photography instead of CT scanning. This digital surface model is sufficient for designing aesthetic implants and avoids the harmful radiation and high cost of CT scans while maintaining the precision needed for customization.
4Device complexity
If traditional fabrication methods are used, then manufacturing process is simplified, but ability to visualize surgical outcomes is lost
Solution Approach 1:
The system provides visual feedback by displaying the designed implant and simulated surgical outcomes to the patient before fabrication. This allows the patient to see and approve the expected results, and enables adjustments to be made based on visual feedback, ensuring satisfaction with the customized implant.
Data Source
AI summary
A method of designing, presenting, generating, and fabricating custom implants by obtaining a 3D image of a site to receive an implant, simulating volumetric changes of the site, generating a virtual 3D implant, and fabricating a real 3D implant. A method of implanting a custom implant in a patient, by obtaining a 3D image of a site to receive an implant, simulating volumetric changes of the site, generating a virtual 3D implant, fabricating a real 3D implant, and implanting the implant in the patient. A method of correcting disfigurement in a patient. A method of replacing a disc in a patient's back. The present invention also provides for an implant fabricated by this method.