Modular Hip Spacer Mold Assembly for Precise Single-Stage Casting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing joint spacers for infected joint endoprostheses, such as hip and shoulder joint spacers, are inefficient and prone to microbial colonization, leading to infection and tissue damage, and require complex two-stage surgical procedures.
Innovation Solution
A modular casting mold system comprising a head element, stem element, and neck element, with latching and form-fitting connections, allows for the production of joint spacers using polymethyl methacrylate bone cement, enabling single-stage assembly and curing of spacers with precise fit and reduced microbial contamination risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plastic casting molds are used for intraoperative production of spacers with PMMA bone cement, then spacers can be produced temporarily to replace infected joint endoprostheses, but the production process is inefficient and prone to microbial colonization
Solution Approach 1:
The casting mold is divided into multiple separable parts (first mold part and second mold part) that can be assembled and disassembled. This segmentation allows for efficient production while enabling proper sterilization of individual components, reducing microbial contamination risk during intraoperative use.
2Ease of manufacture
If traditional casting molds are used, then spacers can be produced, but complex two-stage surgical procedures are required
Solution Approach 1:
The casting mold is designed with pre-integrated alignment features, including a first alignment element on the first mold part and a corresponding second alignment element on the second mold part. These preliminary structural arrangements ensure precise alignment during assembly, simplifying the manufacturing process and enabling single-stage surgical procedures by eliminating the need for complex post-assembly adjustments.
3Manufacturing precision
If casting molds without alignment features are used, then assembly is simpler, but precise fit of spacers cannot be achieved
Solution Approach 1:
The alignment elements are designed to automatically guide and position the mold parts relative to each other during assembly. The first alignment element and second alignment element work together to ensure precise fit without requiring external alignment tools or complex manual positioning procedures, making the precision achievement self-service and reducing operational complexity.
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 system facilitates efficient, single-stage production of joint spacers with reduced microbial contamination, improving surgical outcomes by minimizing infection risk and simplifying the surgical process.
Implementation Method 1
The casting mold comprises a latching element, by means of which an upper shell and a lower shell of the head element and/or of the stem element can be connected to one another
Implementation Method 2
production of spacers using polymethyl methacrylate (PMMA) bone cement
Data Source
AI summary
The invention relates to a casting mold for producing a hip joint spacer, which comprises a head element comprising an upper shell and a lower shell, optionally a neck element, and a stem element, which comprises an upper shell and a lower shell, wherein the casting mold has a latching element, and an upper shell and a lower shell of the head element and/or of the stem element can be connected to one another by means of the latching element.