Custom Implant Fabrication via Intraoperative 3D Shape Modeling
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Solution Overview
Problem
Conventional methods for fabricating implants lack precision and efficiency in customizing implants to match the specific anatomical features of patients, often requiring multiple surgeries and increasing patient risk and cost.
Innovation Solution
A method that involves registering intraoperative locations of a surgically resected anatomical region, generating two-dimensional and three-dimensional representations, and fabricating or modifying implants based on these models to create a customized implant in a single surgical stage, using techniques like additive manufacturing and voxel-additive techniques to mimic biological substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used for fabricating implants, then the manufacturing process is simpler, but the manufacturing precision and customization accuracy deteriorate
Solution Approach 1:
The patent performs preliminary actions by creating a 3D model of the patient's anatomy and designing the custom implant before the actual surgery. This pre-planning phase includes virtual surgical planning and implant design, which allows for precise customization without increasing the complexity of the surgical procedure itself. The implant is fabricated off-site based on these preliminary designs, resolving the contradiction between precision and complexity.
Solution Approach 2:
The patent creates a digital copy or replica of the patient's anatomical structure using imaging data (CT or MRI scans). This digital model serves as a precise template for designing and fabricating the custom implant. By copying the actual anatomy in 3D space, the system achieves high manufacturing precision while keeping the fabrication process manageable through standardized digital workflows and additive manufacturing techniques.
2Loss of time
If conventional implant fabrication methods are used, then the surgical procedure is faster to plan, but the patient requires multiple surgeries increasing overall treatment time
Solution Approach 1:
The patent performs all implant design, customization, and fabrication activities before the surgical procedure. The custom implant is manufactured in advance based on the patient's specific anatomy and surgical requirements. This preliminary action eliminates the need for multiple surgeries, as the precisely fitted implant can be implanted in a single stage, reducing both total treatment time and patient risk associated with repeated surgical interventions.
3Quantity of substance
If conventional methods are used for implant fabrication, then the manufacturing cost is lower, but the patient requires multiple surgeries increasing overall cost
Solution Approach 1:
The patent consolidates multiple surgical procedures into a single stage by performing all planning, design, and implant fabrication activities beforehand. The custom implant is ready for implantation when needed, eliminating the need for separate harvesting and implantation surgeries. This increases surgical efficiency and productivity while reducing overall treatment costs by minimizing the number of surgical interventions, anesthesia events, and hospital stays required.
Data Source
AI summary
The present disclosure relates to methods of; non-transitory, computer-readable media for; and systems for fabricating or modifying an implant. One example embodiment includes a method. The method includes registering a plurality of intraoperative locations of a surgically resected anatomical region of a patient. The method also includes generating, based on the registered plurality of intraoperative locations, a two-dimensional representation of the registered plurality of intraoperative locations. Further, the method includes determining, based on the two-dimensional representation, a two-dimensional shape of an anatomical feature excised from the surgically resected anatomical region. In addition, the method includes determining, based on the two-dimensional shape of the anatomical feature and a three-dimensional model of a portion of the patient that contains the surgically resected anatomical region, a three-dimensional shape of the anatomical feature. Still further, the method includes fabricating or modifying an implant based on the three-dimensional shape of the anatomical feature.