Custom 3D Hernia Mesh with Expandable Hydrogel
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Solution Overview
Problem
Current hernia repair meshes have high recurrence rates due to inadequate fit and coverage of hernia defects and sacs, leading to bowel protrusion and complications like seromas and hematomas, especially in irregular or multiple defect areas, and require extensive surgical time and morbidity.
Innovation Solution
A dual-layer hernia mesh is custom-manufactured based on a 3D map of the hernia defect and volume, featuring a compressible foam or expandable hydrogel front portion that fits exactly into the hernia sac, adhering to tissues and contracting over time to fill the sac volume, while the back portion covers normal muscles and fascia.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flat mesh is used in conventional hernia repair, then the mesh can be easily manufactured and implanted, but the mesh fails to fit irregular hernia defects and sacs, leading to high recurrence rates
Solution Approach 1:
The hernia mesh is divided into two distinct layers: a front portion configured to fit the hernia sac and a back portion configured to cover the hernia defect. This segmentation allows each layer to be optimized for its specific function, with the front portion providing precise fit to irregular sac geometry and the back portion providing structural support for defect coverage.
Solution Approach 2:
The invention transitions from conventional two-dimensional flat meshes to a three-dimensional dual-layer structure. The front portion is shaped to conform to the volumetric geometry of the hernia sac, while the back portion maintains a flatter configuration for defect coverage. This dimensional enhancement enables precise fitting of irregular hernia geometries that cannot be addressed by flat meshes.
2Reliability
If the mesh does not completely fill the hernia sac volume, then implantation is simpler, but bowel can protrude through gaps and recurrence occurs
Solution Approach 1:
The front portion of the mesh is pre-configured with a three-dimensional shape that corresponds to the hernia sac geometry obtained from preoperative imaging. This preliminary shaping ensures that when the mesh is implanted, the front portion automatically conforms to and fills the hernia sac volume, eliminating gaps where bowel could protrude while simplifying the implantation process.
3Productivity
If standard flat meshes are used, then surgical procedure is faster, but the meshes twist, kink, or retract, permitting bowel access to the defect
Solution Approach 1:
The front portion of the mesh is configured with a curved, three-dimensional surface that matches the natural geometry of the hernia sac. This curvature prevents the mesh from twisting or kinking during implantation and ensures stable positioning, as the contoured shape naturally resists deformation and maintains proper orientation within the hernia defect.
4Area of stationary object
If larger incisions are made to accommodate irregular defects, then complete defect coverage is achieved, but surgical morbidity and time increase
Solution Approach 1:
The invention changes the geometric parameters of the mesh from a standard flat configuration to a custom three-dimensional shape that matches the specific hernia defect geometry. This parameter transformation allows the mesh to provide complete coverage of irregular defects while being implantable through standard surgical incisions, thereby reducing surgical time and morbidity associated with larger incisions.
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 custom-fit mesh reduces recurrence rates, minimizes surgical time, and decreases postoperative discomfort and infection risk by ensuring a precise fit and complete sac volume occupation, thereby restoring a normal abdominal contour.
Implementation Method 1
a compressible foam or expandable hydrogel front portion that fits exactly into the hernia sac
Implementation Method 2
an expandable hydrogel front portion that fits exactly into the hernia sac
Data Source
AI summary
A dual-layer hernia mesh can be configured according to a three-dimensional map of a hernia defect(s) and a hernia volume(s) of a patient. The front portion of the mesh can be configured utilizing, for example, a three dimensional map of hernia sac volumes obtained from a CT scan. The front portion of the mesh exactly fits into the hernia sac. The back portion of the hernia mesh is a sheet of mesh material that overlaps over onto the normal muscles and fascia. A “foam” collapsible mesh and/or a flat mesh with expandable hydrogel deposited in variable thickness according to the hernia defect can be utilized as a dual-layer hernia mesh for repair. The hydrogel mesh when combined with water or saline expands and fits into the hernia defect or defects. Both “foam” and hydrogel meshes adhere to the tissues of the hernia sac and then contracts over time. The hernia sac volume slowly disappears, restoring a more normal contour to the abdominal wall.