Hybrid Surgical Guide Structure for Accurate Bone Alignment
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Solution Overview
Problem
Existing surgical guides face challenges in achieving high placement accuracy on patient anatomy while maintaining sufficient rigidity and material strength for guiding surgical instruments, particularly when engaging complex body surfaces.
Innovation Solution
A surgical guide comprising a metal guide with a main plate and an arm, formed through additive manufacturing, integrated with a plastic reference, where the arm is coupled to the plastic reference for precise alignment, utilizing different manufacturing processes for each material to enhance rigidity and compatibility with complex anatomical surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal guide is used to provide rigidity and strength, then the guide can effectively guide surgical instruments, but it becomes difficult to accurately engage complex body surfaces
Solution Approach 1:
The surgical guide is divided into two separate components: a metal guide portion and a separate reference portion. The metal guide provides the necessary strength and rigidity for guiding surgical instruments, while the separate reference portion (made of plastic or ceramic) is specifically designed to engage the complex body surface. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
The surgical guide system combines different materials with complementary properties: metal (for strength and rigidity), plastic (for flexibility and surface engagement), and potentially ceramic (for surface compatibility). This composite approach allows the system to simultaneously achieve the rigidity needed for surgical guidance and the surface engagement capability needed for accurate placement on complex anatomy.
2Ease of manufacture
If a single material is used for the entire surgical guide, then manufacturing is simplified, but it cannot simultaneously provide sufficient strength and surface compatibility
Solution Approach 1:
The surgical guide is divided into two separate components: a metal guide portion and a separate reference portion. The metal guide provides the necessary strength and rigidity for guiding surgical instruments, while the separate reference portion (made of plastic or ceramic) is specifically designed to engage the complex body surface. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
The surgical guide system combines different materials with complementary properties: metal (for strength and rigidity), plastic (for flexibility and surface engagement), and potentially ceramic (for surface compatibility). This composite approach allows the system to simultaneously achieve the rigidity needed for surgical guidance and the surface engagement capability needed for accurate placement on complex anatomy.
3Strength
If metal features are used to engage body surfaces, then strength is sufficient, but there is risk of damage to patient anatomy
Solution Approach 1:
The reference portion acts as an intermediary between the metal guide and the patient's body surface. Made of softer plastic or ceramic material, it provides the necessary engagement strength while being compliant enough to avoid damaging delicate anatomical structures such as teeth or bone surfaces. The metal guide never directly contacts the patient anatomy.
Solution Approach 2:
The material hardness parameter is changed for the portion that contacts the patient anatomy. Instead of using hard metal throughout, the reference portion uses softer plastic or ceramic material that maintains engagement capability while reducing the risk of damage to patient tissues.
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
Improves alignment registration and reduces the risk of anatomical damage by providing precise alignment and rigidity, allowing accurate placement and guiding of surgical instruments on complex patient anatomy.
Implementation Method 1
The first additive manufacturing process can be based on a layer by layer fusion of metal powder using one or more of a laser or an electron beam
Implementation Method 2
The first additive manufacturing process can be based on a layer by layer fusion of metal powder using one or more of a laser or an electron beam
Implementation Method 3
The second additive manufacturing process can be based upon polymer powder fusion (e.g., selective laser sintering of nylon powder)
Implementation Method 4
The second additive manufacturing process can be based upon polymer powder fusion (e.g., selective laser sintering of nylon powder) or polymer resin curing (e.g., stereolithography or selective application of radiation to liquid photocurable resin)
Data Source
AI summary
A surgical guide includes a metal guide and a plastic reference formed by additive manufacturing. The metal guide is configured to engage a bone surface of a first body area. The metal guide includes a main plate and an arm. The main plate has an inner surface customized and shaped to the bone surface. The main plate defines mounting guides for securing the main plate to the bone surface and defines a machining guide for drilling or cutting through the bone surface. The arm is formed to the main plate at a proximal end and extends to a distal end. The plastic reference has a reference surface customized and shaped to a surface of a second body area that is physically separated from the first body area.