Faceted Bone Plate Flat Surface Manufacturing
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Solution Overview
Problem
The variability in anatomical curves between patients complicates the manufacturing and fitting of bone plates, leading to increased manufacturing costs and intraoperative time, and the machining of radial surfaces is expensive and wasteful.
Innovation Solution
The design of bone plates with flat surfaces instead of radial surfaces, which are quicker and cheaper to manufacture, and provide a stable fit by approximating anatomical curves through multiple flat surfaces that extend in various directions, including the use of blockers to secure screws and reduce the risk of plate rocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If radial surfaces with specified radii of curvature are machined to approximate bony surface curvature, then the plate fit to patient anatomy is improved, but manufacturing cost and machine time increase significantly
Solution Approach 1:
The patent divides the continuous radial surface into multiple discrete flat surfaces (facets) that collectively approximate the desired curvature. Each flat surface is defined by simple planar geometry rather than complex radial contours, making them easier to manufacture while maintaining the overall curved appearance and functional fit to the bone surface.
Solution Approach 2:
Instead of machining complex radial surfaces to fit the bone, the patent inverts the approach by using simple flat surfaces that collectively approximate the bone's curvature. This reversal of the traditional design philosophy (from bone-conforming radial surfaces to faceted approximation) simplifies manufacturing while achieving the same functional outcome.
2Manufacturing precision
If radial surfaces are machined with exacting dimensions, then the plate fit and stability are improved, but material waste increases significantly
Solution Approach 1:
By segmenting the surface into discrete flat facets, the patent allows for more efficient material utilization. Each facet can be manufactured independently with standard machining operations, reducing the need for extensive material removal that would be required to create continuous radial surfaces with exacting dimensions.
Solution Approach 2:
The patent changes the geometric parameters from continuous radial curvature definitions to discrete planar facet definitions. This parameter transformation allows the use of standard machining tolerances and simpler manufacturing processes, thereby reducing material waste while maintaining adequate fit and function.
3Adaptability or versatility
If complex radial surfaces are contoured to match patient-specific anatomy, then customization and fit are improved, but intraoperative time increases
Solution Approach 1:
The faceted design allows the plate to be manufactured with pre-defined angular configurations that can be selected to match common anatomical variations. This segmentation into standardized facet patterns enables customization for different patients without requiring complex intraoperative contouring, thereby reducing surgical time.
Solution Approach 2:
The patent performs the anatomical adaptation work during manufacturing rather than during surgery. By pre-configuring the faceted surfaces to match anticipated anatomical variations, the plate arrives at the operating room ready-to-use, eliminating time-consuming intraoperative contouring and customization steps.
Data Source
AI summary
A bone plate that includes an upper surface defined by at least two flat surfaces and a bone contacting surface defined by at least two flat surfaces.