Hybrid Spinal Bone Fastener Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current spinal implant systems face challenges in providing optimal stability and bone integration due to limitations in manufacturing techniques, particularly in addressing the need for complex geometries and enhanced tissue fixation in spinal disorders such as scoliosis, kyphosis, and degenerative disc disease.
Innovation Solution
A hybrid spinal implant system combining traditional manufacturing methods with additive manufacturing techniques, where the proximal portion is fabricated using subtractive methods and the distal portion is created through additive manufacturing, incorporating features like porosity and complex geometries to enhance bone integration and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional manufacturing methods are used for the entire bone fastener, then manufacturing simplicity is maintained, but the ability to achieve complex geometries and enhanced tissue fixation is limited
Solution Approach 1:
The bone fastener is divided into two distinct portions: a proximal portion manufactured by traditional subtractive methods and a distal portion manufactured by additive methods. This segmentation allows each portion to be optimized for its specific manufacturing technique, achieving complex geometries in the distal portion while maintaining manufacturing simplicity in the proximal portion.
Solution Approach 2:
Different manufacturing methods are applied to different portions of the bone fastener based on local requirements. The distal portion, which requires complex geometries for tissue fixation, is manufactured additively, while the proximal portion, requiring high strength and precision, is manufactured subtractively. This local quality approach optimizes each region for its specific functional requirements.
2Reliability
If traditional manufacturing methods are used for the entire bone fastener, then manufacturing simplicity is maintained, but stability and bone integration are compromised
Solution Approach 1:
The bone fastener is segmented into proximal and distal portions with different manufacturing origins. The distal portion, manufactured additively, incorporates complex geometries that enhance bone integration and stability, while the proximal portion provides structural support through traditional manufacturing. This segmentation enables both stability enhancement and manufacturing feasibility.
Solution Approach 2:
The bone fastener effectively combines two different manufacturing 'materials' or approaches: subtractively manufactured metal with high strength properties and additively manufactured structure with enhanced surface geometry for bone integration. This composite approach leverages the advantages of both manufacturing methods to achieve superior overall performance.
3Shape
If additive manufacturing is used for the entire bone fastener, then complex geometries and tissue fixation are enhanced, but manufacturing precision and load support capability are reduced
Solution Approach 1:
The bone fastener is divided into proximal and distal portions, each optimized for its specific manufacturing method. The proximal portion, requiring high manufacturing precision for load support, is manufactured using traditional subtractive methods. The distal portion, requiring complex geometries for tissue fixation, is manufactured using additive methods. This segmentation resolves the contradiction by assigning each function to the appropriate manufacturing technique.
Solution Approach 2:
Different manufacturing qualities are applied to different portions of the bone fastener. The proximal portion achieves high precision and surface quality through subtractive manufacturing, while the distal portion achieves complex three-dimensional geometries through additive manufacturing. This local quality differentiation allows each portion to excel at its specific function without compromising the other.
4Reliability
If additive manufacturing is used for the distal portion, then bone integration is enhanced, but overall device complexity increases
Solution Approach 1:
The bone fastener is segmented into two portions manufactured by different methods. The distal portion uses additive manufacturing to achieve enhanced bone integration through complex geometries, while the proximal portion uses traditional manufacturing. This segmentation allows bone integration enhancement without requiring the entire device to be manufactured with complex additive processes.
Solution Approach 2:
The patent merges two different manufacturing approaches into a single integrated bone fastener device. The proximal and distal portions are combined into one cohesive structure that leverages the advantages of both subtractive and additive manufacturing, achieving enhanced bone integration while maintaining overall device functionality and reliability.
Data Source
AI summary
A bone fastener includes a screw shaft having a proximal portion and a distal portion. The proximal portion is formed by a first manufacturing method and defines a distal face. The distal portion is formed onto the distal face by a second manufacturing method. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed.