Functionalized Implant Surfaces Using Ultrashort Laser Texturing
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Solution Overview
Problem
Existing design and manufacturing modalities for implants face challenges such as lack of bone integration, insufficient soft tissue integration, complex and costly shaping and surface conditioning processes, and issues with machining hard ceramics and leaving heat-affected zones.
Innovation Solution
A medical device manufacturing system that uses computer numerical control (CNC) data to design and shape implants with precise macroscale and microscale surface textures, employing laser ablation and spallation processes to efficiently form implant surfaces and enhance tissue integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional shaping and surface conditioning technologies are used, then implants can be manufactured, but the processes become complex, expensive, and time-consuming with long machine lead times
Solution Approach 1:
The patent combines multiple manufacturing operations (shaping, heat treatment, surface conditioning, and functionalization) into a single integrated laser processing step. The laser system performs macro-shaping, micro-texturing, and chemical functionalization simultaneously, eliminating the need for sequential complex processes and reducing manufacturing steps.
Solution Approach 2:
The patent replaces traditional mechanical machining processes (boring, milling, turning) and chemical etching processes with laser-based processing. The laser system uses photothermal and photochemical effects to directly modify the implant surface, avoiding mechanical tool wear and chemical residue issues.
2Productivity
If fiber lasers are used for surface processing, then material can be removed, but heat-affected zones are created that may damage desired material properties
Solution Approach 1:
The patent transitions from conventional fiber lasers to ultra-short-pulsed lasers (femtosecond or picosecond duration). This drastic reduction in pulse duration changes the heating regime from thermal diffusion to localized photothermal effects, confining energy deposition to the immediate focal volume and preventing heat diffusion to surrounding areas.
Solution Approach 2:
The patent uses ultra-short pulsed laser delivery with precise timing and repetition rates. The periodic pulsed action allows complete cooling of the material between pulses, preventing cumulative thermal effects and heat-affected zones while maintaining high processing speeds through rapid pulse sequencing.
3Reliability
If aggressive chemicals are used for etching, then surface functionalization can be achieved, but toxic chemical residues remain and material composition is modified disadvantageously
Solution Approach 1:
The patent replaces chemical etching processes with laser-induced photochemical and photothermal processes. The ultra-short pulsed laser directly modifies the material surface through controlled ablation and phase transformation, eliminating the need for aggressive chemicals and their associated toxic residues.
Solution Approach 2:
The laser processing creates self-limiting modifications where the material's own properties (absorption coefficient, thermal conductivity, phase transition points) control the functionalization depth and pattern. The process is inherently self-regulating without requiring chemical baths or post-processing cleaning steps.
4Productivity
If conventional lasers are used for machining, then material can be removed, but toxic cooling lubricants and etchants require extensive cleaning
Solution Approach 1:
The patent replaces conventional laser machining with ultra-short pulsed laser processing that eliminates the need for cooling lubricants. The ultra-short pulse duration deposits energy faster than thermal diffusion can occur, creating a cold ablation process that removes material without requiring thermal management fluids.
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 enables efficient design, shaping, and surface functionalization of implants, improving tissue integration and reducing manufacturing complexities and costs, while avoiding heat-affected zones and toxic chemical residues.
Implementation Method 1
an ultra-short-pulsed laser system operable to use the set of laser control parameters to form the microscale surface texture onto the macroscale shape
Implementation Method 2
employing laser ablation and spallation processes to efficiently form implant surfaces
Data Source
AI summary
Various implementations of implants and implant surfaces for clinical rehabilitation or enhancement of a patient, related systems, and computer programs and methods for the design and manufacturing of implants are disclosed. A macroscale shape, a microscale surface texture, and a nanoscale surface topography are overlaid to increase, condition, and thereby functionalize an implant surface. A thin-film coating and/or laser interferometry is utilized to overlay on a machined implant substrate a nanoscale surface topography. Manufacturing the macroscale shape and the microscale texture may be performed with an ultrashort pulsed laser system in separate process steps. The design of a dental implant may be assisted by a self-learning computer program product, based on trained coupled shape models including, for example, mesh-based statistical shape and orientation models.