Helical Telescoping Craniofacial Distractor for 3D Bone Alignment
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Solution Overview
Problem
Craniofacial distractors face challenges in moving bone segments along complex geometrical paths due to size constraints, potential organ/tissue damage, and the need for precise, non-adjustable devices that can be miniaturized and customized for individual patients.
Innovation Solution
A customizable craniofacial distractor with a helical-shaped distraction path, utilizing a steering apparatus with a telescoping inner member and anchoring members, and a distraction drive mechanism, such as a worm-rack drive, to move bone segments along a predetermined path, avoiding condylar displacement and ensuring sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If craniofacial distractors are made small to fit anatomical space, then they can protect the treatment site from external trauma and avoid interfering with daily activities, but they become smaller than the gap they need to create and have limited adjustment capability
Solution Approach 1:
The distractor is divided into multiple segments including a fixed portion and a movable portion that can be independently positioned. The movable portion includes a carriage that travels along a rail, allowing the distractor to create complex three-dimensional distraction paths while maintaining a compact overall size. This segmentation enables the device to achieve both small volume and high adaptability.
Solution Approach 2:
The movable portion is nested within the fixed portion, with the carriage traveling along the rail that is housed within the distractor body. This nesting arrangement minimizes the external dimensions of the device while still providing the necessary range of motion and adjustment capability for complex craniofacial distraction paths.
2Adaptability or versatility
If adjustable devices are designed to allow course changes during activation, then they can adapt to complex geometrical paths, but they become very complicated and difficult to miniaturize
Solution Approach 1:
The distractor is pre-configured with a rail that defines the desired distraction path before surgery. The complex geometrical path is built into the device structure itself, eliminating the need for multiple adjustments during activation. This preliminary action approach reduces device complexity while maintaining the ability to follow complex three-dimensional paths.
Solution Approach 2:
The desired distraction path is first modeled using patient-specific imaging data (CT or MRI scans) to create a virtual plan. The physical distractor is then manufactured to replicate this pre-planned path, with the rail geometry copying the optimal distraction trajectory. This copying approach simplifies the device design while ensuring it follows the complex geometrical path needed for each patient's specific anatomy.
3Device complexity
If rectilinear distractors are used to move bone segments, then the device structure is simple, but they cannot correct complex craniofacial deformities that require three-dimensional movements
Solution Approach 1:
The rail is designed with curved and three-dimensional geometries instead of simple straight lines. The rail can include arcs, helices, or other complex curves that guide the carriage along the optimal distraction path. This curvature enables the distractor to correct complex craniofacial deformities by following the natural three-dimensional geometry of bone movement while adding only moderate complexity to the device structure.
4Adaptability or versatility
If fully adjustable devices with six knobs are used, then comprehensive adjustments are possible, but the operating procedure becomes burdensome and impractical
Solution Approach 1:
The adjustment capability is extracted from the activation process and built into the device structure itself. The rail geometry incorporates the desired distraction path, eliminating the need for multiple knobs and adjustments during activation. The surgeon only needs to activate the distraction mechanism, and the pre-configured rail guides the movement automatically, greatly simplifying the operational burden while maintaining comprehensive adaptability.
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 distractor effectively moves bone segments into desired alignment while preventing tissue damage, maintaining sterility, and fitting within anatomical constraints, providing a stable and efficient surgical outcome.
Implementation Method 1
The distraction drive mechanism may include at least one of a worm-rack drive, flexible wires, friction-ratchet mechanism, and a hydraulic mechanism. When the distraction drive mechanism comprises a worm-rack drive, the worm-rack drive may include a worm gear rotatably coupled to the outer sleeve where the worm gear is threadably coupled to a toothed surface provided on the inner member, such that rotation of the worm gear causes the inner member to move along the distraction path.
Implementation Method 2
The steering apparatus may include an outer sleeve and a telescoping inner member. The steering apparatus is movable along the helical-shaped distraction path to create gap between the first and second bone segments.
Data Source
AI summary
The present disclosure is directed to a customizable distractor for oral and maxillofacial surgery and a system and method for designing and making the same. The distractor includes a steering apparatus that is movable along the helical-shaped distraction path to create gap between the first and second bone segments, an anchoring member for coupling the steering apparatus a first and second bone segment, and a distraction drive mechanism is used to drive movement of the steering apparatus along the distraction path.