Modular Bone Cement Mold Segments for Custom Orthopedic Spacers

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Solution Overview

Problem

Current orthopedic implants for joint replacements lack customizability, modularity, and cost-effectiveness, particularly in providing axial stability and accommodating varying patient sizes and bone loss scenarios, leading to complications during revision surgeries and infections due to inadequate soft tissue maintenance and limited antibiotic delivery options.

Innovation Solution

A modular mold system for forming temporary implants using bone cement, allowing customization of sizes and shapes through templated mold segments with open channels for cement flow and optional reinforcement members, enabling surgeons to tailor antibiotic mixtures and fabricate implants in situ, accommodating various joint types and bone loss conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pre-fabricated antibiotic-laden spacers are used, then infection prevention is improved, but customization for varying patient sizes and bone loss scenarios deteriorates

Engineering Contradiction:

Improveinfection preventionVSAvoidcustomization for patient sizes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The mold system is divided into multiple interchangeable mold segments that can be assembled in different configurations to create custom-length spacers. Each mold segment corresponds to a specific anatomical region, allowing surgeons to assemble molds matching the patient's specific bone loss extent and anatomical requirements while maintaining standardized antibiotic delivery functionality.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If custom implants are fabricated for each patient, then adaptability to patient anatomy is improved, but manufacturing complexity and cost deteriorates

Engineering Contradiction:

Improvecustomization for patient anatomyVSAvoidmanufacturing system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mold system uses standardized, interchangeable mold segments that can be assembled like building blocks. This segmentation allows custom spacer fabrication without requiring entirely custom molds for each patient - instead, surgeons select and assemble pre-manufactured mold segments from a standardized library, dramatically reducing manufacturing complexity while maintaining customization capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold segments are designed with universal connection interfaces and standardized features that allow the same mold components to be used across different spacer configurations and patient anatomies. This universality enables a single set of mold segments to serve multiple functions and create various custom implants, reducing the overall manufacturing burden.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If modular mold segments with open channels are used, then ease of cement filling is improved, but mold complexity increases

Engineering Contradiction:

Improveease of cement fillingVSAvoidmold structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The mold is segmented into modular sections with integrated open channels that run through each segment. These channels provide direct pathways for bone cement injection, allowing cement to flow easily through the entire mold structure during fabrication. The segmentation allows the channels to be built into the basic mold architecture rather than added as complex external routing.

Inventive Principle:

Principle #1Segmentation

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 modular system provides customizable, cost-effective temporary implants that maintain axial stability, reduce infection risks, and facilitate safer re-implantation by allowing tailored antibiotic delivery and accommodating diverse patient anatomies, enhancing surgical efficiency and patient recovery.

Implementation Method 1

each segment having an open channel. The channels of connected mold segments are aligned and a reinforcement member on a centralizing holder positioned through the channels and into the mold segments. After bone cement is mixed, at least some cement is poured through the open channels and into the connected mold segments

Methodology Applied

Scientific EffectFluid flow through channels:

Implementation Method 2

a reinforcement member on a centralizing holder positioned through the channels and into the mold segments

Methodology Applied

Scientific EffectGravitational force: Gravitation

Implementation Method 3

the mold is steadily held in place until the cement cures

Methodology Applied

Scientific EffectPolymerization curing: Photopolymerisation

Data Source

PatentUS7867426B2Method of forming a temporary implant

Publication Date: 2011.01.11 ZIRAN BRUCE H

AI summary

A mold assembly and method of forming a surgical implant from bone cement. The method has the steps of connecting a plurality of mold segments to approximate the size of a patient implant. Each mold segment has an open channel. The method may further include aligning the channels of connected mold segments, positioning a centralizing holder on a reinforcement member, mixing bone cement, pouring at least some bone cement through the channels and into connected mold segments, fitting the reinforcement member into the mold segments, curing the bone cement; and removing the cured surgical implant.