3D Printed Mesh Implants with Hollow Compartments for Bone Graft Delivery
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Solution Overview
Problem
Traditional 3D printing methods do not allow for the creation of a mesh implant with hollow compartments that can be filled with bone material, limiting the ability to customize and effectively deliver bone grafts for bone repair, as they are not biodegradable and do not conform to the implant site.
Innovation Solution
A computer-implemented method and system for generating a 3D digital model of a mesh implant with compartments to enclose bone material, using a 3D printer to create a seamless mesh implant that can be filled with autograft, allograft, or demineralized bone matrix, and a covering can be printed to enclose the bone material, allowing for customizable and biodegradable bone graft delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional 3D printing methods are used to create solid objects layer by layer, then manufacturing capability is achieved, but the ability to create hollow compartments for bone material filling is lost
Solution Approach 1:
The mesh implant is divided into multiple hollow compartments that can be separately filled with different bone materials. The continuous mesh structure is segmented into discrete filling zones, allowing customized bone graft delivery to different regions of the implant site.
Solution Approach 2:
The patent transitions from traditional layered 3D printing to a continuous extrusion process that creates three-dimensional hollow structures in a single continuous operation. This dimensional approach allows the mesh to enclose volumetric spaces while maintaining structural integrity.
2Strength
If traditional 3D printing creates solid multi-layered objects, then structural integrity is achieved, but conformability to implant site and biodegradability are compromised
Solution Approach 1:
The mesh implant is constructed as a flexible, thin-walled continuous structure that can conform to the contours of the implant site. The mesh geometry allows the implant to adapt to irregular bone defect shapes while maintaining sufficient structural integrity to hold bone materials.
Solution Approach 2:
The patent utilizes biodegradable materials and controls the mesh geometry parameters to achieve optimal balance between structural strength and conformability. The mesh size, wall thickness, and overall geometry are optimized to provide adequate strength while allowing the implant to conform to the implant site and eventually degrade as bone regenerates.
3Ease of operation
If bone grafts are delivered in solid monolithic form, then implantation simplicity is achieved, but customization and ability to add autograft are limited
Solution Approach 1:
The mesh implant divides the bone graft delivery into multiple compartments that can be filled with different types of bone materials (allograft, autograft, demineralized bone matrix). This segmentation allows customized composition while maintaining a single implantable device.
Solution Approach 2:
The mesh implant structure is pre-formed with hollow compartments ready to receive bone materials. The mesh can be filled with allograft or demineralized bone matrix before implantation, and the design allows for subsequent addition of autograft materials during surgery, combining preparation simplicity with intraoperative customization.
4Manufacturing precision
If discontinuous layer-by-layer printing is used, then material deposition control is achieved, but continuous extrusion capability and productivity are reduced
Solution Approach 1:
The patent employs a continuous extrusion process where the mesh implant is formed in a single uninterrupted printing operation. The extrusion head continuously deposits material to create the mesh structure and hollow compartments without stopping to remove and replace layers, significantly improving manufacturing efficiency while maintaining precise control over the mesh geometry and compartment formation.
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 a customizable, biodegradable mesh implant that can be filled with various bone materials, improving bone graft delivery and integration by allowing for continuous extrusion and conforming to the implant site, enhancing bone repair and regeneration.
Implementation Method 1
Three-dimensional (3D) printing is an additive printing process used to make three-dimensional solid objects from a digital model. 3D printing techniques are considered additive processes because they involve the application of successive layers of material to make the object being printed.
Implementation Method 2
3D printing does not allow for continuous extrusion to create an object. The patent enables continuous extrusion to create a seamless mesh implant having one or more compartments that can be filled with bone material.
Data Source
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AI summary
Computer implemented methods of producing a mesh implant having a compartment to enclose a bone material therein are provided. These methods include generating a 3D digital model of the mesh implant having the compartment, the 3D digital model including a virtual volume of the compartment and a virtual depth, thickness and volume of the mesh implant; generating a 3D digital model of a covering configured for closing the compartment of the mesh implant, the 3D digital model including a virtual volume of the covering for closing the compartment of the mesh implant; and instructing a 3D printer coupled to a computer to generate the mesh implant based on the 3D digital models. A computer system for making a mesh implant and a delivery system including the mesh implant are also provided.