Patient-Specific Jaw Distractor via 3D Printing
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Solution Overview
Problem
Conventional jaw distractors face issues with inaccurate fitting, increased operating time, and susceptibility to fractures and soft tissue irritation due to high inter-individual variability in mandibular anatomy, leading to unpredictable force vectors and complications during orthodontic procedures.
Innovation Solution
A method involving 3D imaging and 3D printing to create patient-specific distractors that are precisely adapted to individual anatomical features, reducing the need for intraoperative adjustments and minimizing exposure to radiation, using titanium 3D printing for the skeletal portion and standard elements for other parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If prefabricated distractor systems are used, then manufacturing cost and availability are improved, but fitting accuracy and force vector predictability deteriorate due to high inter-individual variability in mandibular anatomy
Solution Approach 1:
The invention performs preliminary actions by creating a virtual model of the patient's jaw using 3D imaging data before the actual surgery. The distractor is designed and adapted to the individual patient's anatomy in advance, allowing precise fitting without intraoperative adjustments. This preliminary digital planning and customization resolves the contradiction by maintaining ease of manufacture through standardized 3D printing processes while achieving high fitting accuracy through patient-specific adaptation.
2Adaptability or versatility
If prefabricated distractor systems are adapted intraoperatively, then adaptability to individual patient anatomy is improved, but operating time and material weakening due to torsion and bending increase
Solution Approach 1:
The invention moves the adaptation process from intraoperative to preoperative stages by using 3D imaging and virtual modeling. The distractor is customized to the patient's anatomy before surgery, eliminating the need for time-consuming intraoperative adjustments. This resolves the contradiction by maintaining full adaptability to individual anatomy while significantly reducing operating time.
Solution Approach 2:
The invention replaces the mechanical adaptation process (manual bending and torsion of prefabricated distractors during surgery) with a digital design and 3D printing process. This substitution eliminates material weakening due to mechanical stress while maintaining adaptability, and reduces operating time by performing adaptation outside the surgical procedure.
3Adaptability or versatility
If prefabricated distractor systems are adapted intraoperatively, then adaptability to individual patient anatomy is improved, but the transition area between skeletal fixation and transgingival part shows increased susceptibility to fractures
Solution Approach 1:
The invention performs preliminary design and adaptation using 3D virtual modeling, allowing the transition area between skeletal fixation and transgingival part to be optimized for each patient's anatomy before manufacturing. This eliminates the need for intraoperative bending and torsion that create weak points, thereby maintaining adaptability while significantly reducing fracture susceptibility.
Solution Approach 2:
The invention replaces mechanical adaptation (bending and torsion) with additive manufacturing (3D printing). This substitution allows the transition area to be designed with optimal geometry and material distribution from the beginning, eliminating stress concentrations and material weakening that lead to fractures, while maintaining full adaptability to individual anatomy.
4Manufacturing precision
If 3D imaging and 3D printing are used to create patient-specific distractors, then fitting accuracy and reduction of operating time are improved, but exposure to radiation increases
Solution Approach 1:
The invention performs preliminary 3D imaging and virtual modeling to create an accurate digital representation of the patient's jaw anatomy. This allows precise distractor design without requiring repeated imaging during surgery. The radiation exposure is limited to the initial scanning phase, while the benefits of high fitting accuracy are achieved through digital planning and 3D printing.
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
This approach results in a distractor with improved accuracy of fit, reduced operating time, minimized complications, and enhanced patient recovery outcomes by allowing for precise adaptation to anatomical conditions, reducing the risk of nerve damage and soft tissue irritation.
Implementation Method 1
3D printing the distractor or parts thereof from the virtual model
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
The invention relates to a method for producing a distractor for skeletal fixation to a patient's jaw. According to the invention, the method comprises the following steps: (a) producing a three-dimensional image of the patient's jaw or parts of the jaw; (b) producing a virtual model of a patient-specific distractor using the three-dimensional image; and (c) producing the distractor or parts thereof on the basis of said virtual model.