In-situ Channeled Spinal Implants via Additive Manufacturing
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Solution Overview
Problem
Conventional additively manufactured medical implants are not customized to patient anatomy, face access issues during implantation, and incur high costs due to off-site manufacturing, labor-intensive assembly, and challenges in precise positioning.
Innovation Solution
A surgical additive-manufacturing system that allows for in-situ formation of channeled spinal implants using a dispensing component, a robotic subsystem, and a controller apparatus to position and apply printing material selectively, forming multiple surfaces, openings, and elongate channels within the interbody space between vertebrae.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional implants are pre-manufactured in mass quantities, then manufacturing cost per unit is reduced, but customization to patient anatomy is lost
Solution Approach 1:
The system enables self-service manufacturing by allowing the implant to be fabricated directly at the surgical site using the patient's own anatomy as the mold. The dispensing component deposits material that solidifies to form a custom-fit implant without requiring pre-manufacturing, thus achieving both customization and operational efficiency.
Solution Approach 2:
The system performs preliminary scanning and planning actions before surgery to pre-determine the implant geometry based on patient anatomy. This preliminary action enables customization while the actual manufacturing occurs during surgery, combining pre-planning benefits with intraoperative customization.
2Manufacturing precision
If conventional implants are pre-manufactured off-site, then manufacturing precision can be controlled, but access issues arise during implantation
Solution Approach 1:
The system performs preliminary scanning and digital planning to establish precise implant geometry before surgery. This pre-planning ensures manufacturing precision while the actual implant fabrication occurs in-situ during surgery, eliminating access issues associated with delivering pre-manufactured implants through narrow surgical corridors.
3Reliability
If conventional implants are pre-manufactured, then quality control can be maintained, but costs increase due to packaging, shipping, tracking, and storage
Solution Approach 1:
The system eliminates the need for external logistics operations (packaging, shipping, tracking, storage) by enabling self-service manufacturing at the point of use. The implant is fabricated directly in the surgical suite from digitally planned parameters, maintaining quality control through automated manufacturing while eliminating all associated logistics costs.
4Ease of operation
If conventional implants are assembled manually in the operating room, then flexibility in assembly is maintained, but labor time and complexity increase
Solution Approach 1:
The system merges the scanning, planning, manufacturing, and implantation steps into a single integrated workflow. The dispensing component is guided by the robotic subsystem to deposit material directly in the desired implant configuration, combining what were previously separate manual assembly operations into one automated process, thereby reducing time while maintaining flexibility through digital control.
5Reliability
If conventional implants use a single large central cavity for bone growth, then bone ingrowth is promoted in one location, but ingrowth is limited to one direction
Solution Approach 1:
The system divides the single large central cavity into multiple smaller cavities or channels distributed throughout the implant structure. This segmentation allows bone ingrowth to occur in multiple locations and directions simultaneously, enhancing the versatility of bone integration while maintaining reliable osteogenesis through increased surface area and distributed growth pathways.
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
Enables the creation of custom-fit implants with precise geometry and positioning, reducing costs and labor, and overcoming access challenges by manufacturing implants directly in the patient, thereby improving implantation efficiency and reducing post-surgical complications.
Implementation Method 1
a surgical additive-manufacturing system having a dispensing component... maneuvering, in an applying step, the dispensing component within the interbody space and depositing, by the dispensing component, printing material on or adjacent the first vertebra to form the implant
Data Source
AI summary
A method for growing a channeled spinal implant in situ, using a surgical additive-manufacturing system having a dispensing component, and implants formed thereby. The method can include positioning the dispensing component at least partially within an interbody space, between a first patient vertebra and a second patient vertebra, and maneuvering, in an applying step, the dispensing component within the interbody space and depositing, by the dispensing component, printing material on or adjacent the first vertebra. The applying step includes maneuvering the dispensing component and applying the printing material selectively to form an outer surface of the implant having a channel opening and to form an interior of the implant having at least one elongate channel extending to the opening.