Patient-Specific Intercalary Prosthesis With Lattice Connector Assembly
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Solution Overview
Problem
Existing reconstruction implants for intercalary skeletal defects in long bones are not patient-specific, often resulting in awkward bone geometries and inconsistent limb lengths, and are difficult to implant due to their weight and assembly challenges.
Innovation Solution
A patient-specific intercalary prosthesis with intramedullary components and a connector component featuring a lattice structure and customizable curvature, utilizing additive manufacturing for lightweight construction and secure locking mechanisms, allowing for precise assembly and alignment with the patient's anatomy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional reconstruction implants are used, then the bone defect can be bridged, but the implant is heavy and difficult to implant
Solution Approach 1:
The connector component incorporates a lattice structure with porous characteristics that reduces implant weight while maintaining structural integrity. The lattice design provides sufficient strength to bridge the bone defect while being significantly lighter than solid traditional implants, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The prosthesis combines different materials with complementary properties: the intramedullary components are made of metal for strength and bone compatibility, while the connector component uses a lattice structure that optimizes the strength-to-weight ratio. This composite approach allows each component to be optimized for its specific functional requirements.
2Strength
If traditional reconstruction implants are used, then the bone defect can be bridged, but the assembly is difficult and time-consuming
Solution Approach 1:
The prosthesis is divided into three separate components: two intramedullary components that fit into the bone segments and a connector component that bridges the defect. This segmentation allows each component to be manufactured independently with optimized geometry and simplifies the assembly process, as components can be separately implanted and then connected through the lattice structure.
Solution Approach 2:
The intramedullary components are designed to be inserted into the intramedullary canals of the bone segments, nesting within the existing bone anatomy. The connector component then connects these nested components, creating a hierarchical assembly structure that simplifies implantation while maintaining structural stability.
3Strength
If non-patient-specific implants are used, then the bone defect can be bridged, but the bone geometry becomes awkward and limb length is inconsistent
Solution Approach 1:
The intramedullary components are customized to match the specific geometry of each patient's bone segments, ensuring optimal fit and load distribution. The connector component's lattice structure can also be tailored to the specific defect geometry. This local customization maintains natural bone geometry and limb length while providing the necessary load-bearing capacity.
Data Source
AI summary
An intercalary prosthesis for spanning portions of a long bone includes a first intramedullary component that has a first stem and a first connector disposed at one end of the first stem. The first stem is configured to be received within an intramedullary canal of a long bone. A second intramedullary component has a second stem and a second connector disposed at one end of the second stem. The second stem is configured to be received within an intramedullary canal of the long bone. The prosthesis also includes a connector component. The connector component has a body that includes opposing ends each with a connector configured to respectively connect to the connectors of the first and second intramedullary components. The body also has an outer shell and an inner lattice structure disposed within and connected to the outer shell.