Customized Medical Device Design via Warping Interpolation

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Solution Overview

Problem

Current methods for customizing medical devices, such as surgical plates, are time-consuming, costly, and prone to errors due to the need for manual adjustments during surgeries, leading to prolonged anesthesia times, increased infection risks, and device failure from corrosion and stress fatigue.

Innovation Solution

A method and system for designing and fabricating customized medical devices using computer-aided manufacturing techniques, involving the modification of digital models through warping interpolation functions to precisely fit patient anatomy, enabling efficient, standardized, and cost-effective production of custom devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual adjustments are made to generic medical devices during surgery, then the device can be adapted to fit patient anatomy, but surgery time is prolonged and infection risk increases

Engineering Contradiction:

Improvedevice adaptability to patient anatomyVSAvoidsurgery time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by customizing medical devices before surgery through a digital workflow. Patient-specific 3D models are created from medical imaging data, and devices are designed and manufactured in advance to precisely fit the patient's anatomy. This eliminates the need for time-consuming manual adjustments during surgery, directly resolving the contradiction between device adaptability and surgery time.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If manual adjustments are made to medical devices during surgery, then the device can be adapted to fit patient anatomy, but infection risk and device failure risk increase

Engineering Contradiction:

Improvedevice adaptability to patient anatomyVSAvoiddevice reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent implements preliminary customization of devices to precisely fit patient anatomy before surgery. By manufacturing patient-specific devices in advance with exact anatomical matching, the need for intraoperative manual adjustments is eliminated. This prevents device corrosion and stress fatigue at adjustment points, directly improving device reliability while maintaining adaptability.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If customised medical devices are produced using traditional methods, then patient-specific fit is achieved, but cost and production time increase

Engineering Contradiction:

Improvedevice fit to patient anatomyVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical manufacturing methods with additive manufacturing (3D printing). The digital workflow converts patient imaging data into 3D models, which are then manufactured using additive processes. This substitution enables rapid production of complex patient-specific devices with high precision while significantly improving production efficiency and reducing costs compared to traditional manufacturing methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes parameter changes in additive manufacturing technology to achieve both high manufacturing precision and improved productivity. By adjusting printing parameters, material selection, and layer thickness, the system can produce patient-specific devices with exact anatomical fit while maintaining rapid production rates. This resolves the contradiction between precision and productivity.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If additive manufacturing is used for medical devices, then production flexibility and customization are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedevice customization capabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by creating a standardized digital workflow that handles multiple device types through a common process. The same software platform and additive manufacturing system can produce various medical devices (implants, surgical guides, patient-specific instruments) from different anatomical data sources. This multi-functionality reduces manufacturing process complexity despite high customization capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11963889B2System for designing and fabricating a customised device

Publication Date: 2024.04.23 3DMORPHIC PTY LTD

AI summary

Disclosed herein are a method and system for producing a digital model of a customised device, comprising the steps of: importing a first digital file of a base part; importing a second digital file of a target shape; determining a warping interpolation function based on source point positions associated with the base part and target point positions associated with the target shape; and applying the warping interpolation function to the points of said base part to generate a model of said customised device.