Foamable 3D-Printed Bone Implants With Patient-Matched Density
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Solution Overview
Problem
Current orthopedic implants lack patient specificity and biological interaction, often resulting in issues such as stress shielding, bone resorption, and poor osseointegration due to mismatched modulus of elasticity, and are non-biodegradable, necessitating subsequent surgical procedures.
Innovation Solution
A method for 3D printing patient-specific bone implants using a foamable thermoplastic composition comprising bioactive agents and chemical foaming agents, adjusting the 3D printing temperature to achieve varying densities and mechanical properties that match the patient's bone structure, utilizing FDM 3D printing for improved flexibility and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional orthopedic implants are used, then structural support is provided, but patient specificity and biological interaction are lacking, resulting in stress shielding, bone resorption, and poor osseointegration
Solution Approach 1:
The patent applies local quality by varying the density and material composition at different locations within the implant structure. The 3D printing process enables region-specific control of porosity and mechanical properties to match the patient's bone structure, improving both adaptability and osseointegration simultaneously
Solution Approach 2:
The patent uses composite materials combining thermoplastic polymers with bioactive agents and chemical foaming agents. This composite approach enables the implant to provide structural support while simultaneously promoting bone growth and achieving patient-specific mechanical properties
2Duration of action of stationary object
If non-biodegradable materials are used for implants, then structural durability is maintained, but subsequent surgical procedures are required for removal
Solution Approach 1:
The patent applies parameter changes by selecting thermoplastic materials with specific degradation characteristics. The implant can be designed with controlled biodegradation rates that match bone regeneration, allowing temporary structural support without requiring removal surgery
Solution Approach 2:
The patent embraces the concept of temporary implants by using biodegradable thermoplastic materials. The implant serves its structural purpose during bone healing and then naturally degrades, eliminating the need for removal procedures
3Ease of manufacture
If uniform density implants are produced, then manufacturing simplicity is maintained, but mismatched modulus of elasticity occurs relative to patient bone structure
Solution Approach 1:
The patent applies dynamics by implementing variable density and material distribution throughout the implant structure. The 3D printing process enables dynamic adjustment of mechanical properties at different locations to match the patient's bone modulus of elasticity while maintaining manufacturing efficiency
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
The method produces implants with improved interaction and regeneration by mirroring the patient's bone density and structure, reducing negative impacts on surrounding tissues and eliminating the need for subsequent surgeries.
Implementation Method 1
between about 0.5% and about 10% chemical foaming agent by weight
Implementation Method 2
causing, by the computing hardware, a 3D printer to form the patient-specific bone implant from the 3D image using the thermoplastic polymer by modifying a 3D printing temperature of the 3D printer
Implementation Method 3
The 3D printer comprises a heating element and a cooling element
Data Source
AI summary
A method for 3D printing a patient-specific bone implant having variable density, in various aspects, comprises: (1) providing a thermoplastic polymer composition comprising: (A) between about 20% and about 50% bioactive agent by weight; (B) between about 0.5% and about 10% chemical foaming agent by weight; and (C) balance structural polymer by weight; (2) receiving, by computing hardware, a scan of a bone, the scan comprising at least a 3D image of the bone and radiodensity data for the bone; and (3) causing, by the computing hardware, a 3D printer to form the patient-specific bone implant from the 3D image using the thermoplastic polymer by modifying a 3D printing temperature of the 3D printer during printing of the patient-specific bone implant such that each portion of the patient-specific bone implant is produced at a temperature that corresponds to a desired density defined by the radiodensity data for the bone.