Custom Ceramic Bone Blocks via 3D Printing

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Solution Overview

Problem

Current methods for filling bone defects in the mandible or maxilla face challenges such as shape and quantity issues with standard-sized bone blocks, leading to stability problems, osseointegration issues, and risks of fracture and tissue injury, along with the need for additional surgical sites for autografts.

Innovation Solution

The use of 3D printing technology to create custom ceramic blocks with controlled three-dimensional networks of channels, allowing for precise adaptation to bone defects, improved osseointegration, and programmed resorption, eliminating the need for intraoperative retouching and reducing surgical complications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If standard-sized bone blocks are used for filling bone defects, then the procedure is simpler and avoids custom manufacturing, but the blocks require intraoperative reshaping which causes stability problems, fracture risks, and poor osseointegration

Engineering Contradiction:

Improvesimplicity of procedureVSAvoidstability and osseointegration

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The bone block is pre-adapted to the exact shape of the bone defect using patient-specific 3D imaging data before surgery. The digital planning software allows virtual adaptation of the graft to the defect, and the custom-manufactured block is produced in advance with the precise geometry needed, eliminating the need for intraoperative reshaping and ensuring optimal fit and stability from implantation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention creates a precise copy or replica of the patient's actual bone defect geometry using 3D imaging (CT or MRI) and digital modeling. The custom bone block is manufactured to match the defect's exact shape, size, and contours, allowing perfect adaptation without intraoperative modification and ensuring stable integration with the surrounding bone tissue.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If intraoperative reshaping of standard blocks is performed to adapt them to bone defects, then standard blocks can be used, but sharp edges are created that damage soft tissues and hinder healing

Engineering Contradiction:

Improveadaptability to bone defectVSAvoidsoft tissue damage

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the manufacturing parameters and process from standard off-the-shelf blocks to custom 3D-printed blocks with controlled surface properties. The additive manufacturing process allows precise control over surface roughness, porosity, and geometry, creating surfaces that are biocompatible and promote soft tissue integration without the harmful sharp edges created by intraoperative reshaping.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If autografts are used to fill large bone defects, then living bone cells are provided for regeneration, but additional surgical sites are required causing complications and limiting the quantity available

Engineering Contradiction:

Improvebone regeneration capabilityVSAvoidnumber of surgical sites

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The custom bone block incorporates a porous structure with controlled porosity and interconnected channels that mimic natural bone architecture. This porous framework allows infiltration and colonization by patient's own bone cells and blood vessels, providing the biological environment needed for regeneration without requiring harvesting from additional surgical sites. The porosity can be optimized during digital planning to match the specific regenerative needs of the defect.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention uses composite materials combining synthetic bone substitutes (such as hydroxyapatite, beta-tricalcium phosphate, or bioglass) with a porous structure that supports cellular infiltration. These composite materials provide both the structural framework for large defect filling and the biological properties for osteoconduction and osteoinduction, replacing the need for autograft harvesting while maintaining regenerative capabilities.

Inventive Principle:

Principle #40Composite materials

4Manufacturing precision

If 3D printing is used to create custom ceramic blocks, then perfect adaptation to bone defects is achieved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveadaptation to bone defectVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention replaces traditional mechanical manufacturing methods (cutting, shaping, and fitting of standard blocks during surgery) with additive manufacturing (3D printing). The 3D printing process builds the custom bone block layer by layer according to digital models derived from patient imaging, achieving precise anatomical adaptation without the complexity of intraoperative mechanical reshaping and providing benefits such as reduced surgical time and improved fit.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a stable, well-integrated bone fill solution with reduced risk of fracture and improved tissue healing, eliminating the need for additional surgical sites and ensuring complete bone healing for successful implant placement.

Implementation Method 1

produce, using additive manufacturing techniques—which can also be called stereolithography or 3D printing—synthetic blocks of ceramic material perfectly adapted to the bone defects of patients

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Implementation Method 2

create the body of the block with sufficient 'porosity' allowing colonization by bone cells and neovascularization (formation of new blood vessels)

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentEP3203934B1Synthetic block intended for filling in a bone defect and method for manufacturing same

Publication Date: 2023.09.06 S A S 3DCERAM SINTO

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AI summary

The present invention relates to a synthetic block intended for filling in a bone defect, characterised by the fact that it is made up of a part (11) made of ceramic material which has a shape that enables same to fill in the bone defect, and which is capable of being stabilised once placed in said bone defect, a three-dimensional network of channels communicating with one another being formed at least partially in said part (11) such as to allow through the fluids and cells that enable revascularisation with a view to cell growth once said part (11) is in place in the bone defect, said channels opening onto each surface of the bone defect in contact with said part (11) once it is placed in the bone defect.