Implant Scaffold Vent Openings for Gas-Vented Molding

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Solution Overview

Problem

Medical implants, particularly orthopaedic implants, are costly to manufacture due to strict tolerances, sterility requirements, incorporation of pores that weaken the structure, and complex shapes, making machining difficult.

Innovation Solution

Incorporating vent openings in a scaffold within a mold cavity to allow gas escape during molding while minimizing the flow of molding material, enabling rapid and economical production of implants with varied shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vent openings are made larger to allow gas escape, then gas venting improves, but molding material may flow through the opening

Engineering Contradiction:

Improvegas ventingVSAvoidmolding material flow control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The vent opening is equipped with a mold insert post that creates a localized clearance zone. This clearance has specific dimensional properties (larger than gas molecules but smaller than molding material) that differ from the rest of the implant structure, allowing selective passage of gas while blocking molding material.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The clearance dimensions are carefully controlled to fall within a specific range that permits gas flow while preventing molding material flow. By adjusting the clearance size parameter, the system achieves selective permeability based on the size difference between gas molecules and molding material particles.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If traditional machining methods are used to ensure strict tolerances and sterility, then implant quality improves, but manufacturing cost and time increase

Engineering Contradiction:

Improvetolerance and sterilityVSAvoidmanufacturing cost and time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention replaces traditional mechanical machining processes with a molding process. The mold insert post and clearance structure are formed through molding rather than precision machining, eliminating the need for expensive and time-consuming mechanical operations while maintaining the required clearance dimensions for gas venting.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The molding process utilizes phase transitions of molding material (from liquid/injected state to solidified state) to form the implant structure with integrated vent openings. This phase change-based forming method achieves complex geometries and precise clearances more efficiently than mechanical machining.

Inventive Principle:

Principle #36Phase transitions

3Adaptability or versatility

If pores are incorporated to encourage tissue ingrowth, then biological integration improves, but structural strength decreases

Engineering Contradiction:

Improvetissue ingrowthVSAvoidstructural strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The implant is segmented into two functional zones: porous regions that facilitate tissue ingrowth and denser regions (including the barrier layer and vent opening structures) that provide structural strength. This segmentation allows the implant to simultaneously achieve biological integration and mechanical integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The implant utilizes composite material distribution with varying porosity levels. The barrier layer and vent opening structures employ materials or configurations with lower porosity for strength, while other regions maintain higher porosity for tissue ingrowth, creating a composite structure that balances both requirements.

Inventive Principle:

Principle #40Composite materials

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 method reduces the risk of bubble formation and enhances cooling rates, allowing for efficient and cost-effective manufacturing of implants with complex shapes.

Implementation Method 1

gas flows through the clearance without molding material flowing through the clearance during the injecting

Methodology Applied

Scientific EffectGas flow through clearance:

Implementation Method 2

the at least one vent opening and the at least one mold insert post forming a clearance therebetween; and injecting molding material into the mold cavity to fill the mold cavity and form the implant such that gas flows through the clearance

Methodology Applied

Scientific EffectGas venting:

Implementation Method 3

which can reduce the risk of bubbles undesirably forming in the formed implant and increase the cooling rate of the molding material

Methodology Applied

Scientific EffectCooling rate enhancement: Cooling

Data Source

PatentUS12589535B2Medical implants with vent openings for molding

Publication Date: 2026.03.31 SMED TA TD LLC

AI summary

A method of forming an implant includes: placing a porous scaffold having a plurality of pores formed therein in a mold part cavity of a mold cavity of a mold, the porous scaffold including two portions of biocompatible material and a barrier layer disposed between the two portions, the barrier layer including a solid sheet having a plurality of vent openings that are sized to allow gas to vent therethrough; and injecting molding material into the mold cavity to fill the mold cavity and form the implant, wherein at least some of the gas in the mold cavity vents through the vent openings during the injecting.