Modular Bone Graft Cage Interlocking Mechanism
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Solution Overview
Problem
Current bone grafting methods for large bone defects are inefficient due to the time-consuming nature of hand-formed 2D sheets and the high costs associated with patient-specific implants, which often result in suboptimal outcomes.
Innovation Solution
A modular bone graft cage system comprising cross-sectional portions with interlocking mechanisms, allowing for customizable assembly and interconnection of cages to create anatomically specific constructs, utilizing 3D printing techniques with polymers or metals for enhanced flexibility and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If prefabricated 2D sheets are formed by hand to shape, then the bone graft can be customized to fit the patient's anatomy, but the process is time-consuming and leads to poor results if the shape is not constructed well
Solution Approach 1:
The bone graft cage is divided into multiple modular cross-sectional portions that can be independently manufactured and then assembled together. Each portion can be pre-formed with precise geometry, eliminating time-consuming hand-shaping in the operating room while maintaining the ability to customize the overall shape by selecting and assembling appropriate modules.
Solution Approach 2:
The cross-sectional portions are pre-formed with precise geometries before the surgical procedure. This preliminary preparation allows the bone graft to be customized to fit the patient's anatomy without requiring time-consuming manual shaping during the operation, thus reducing operation room time while maintaining adaptability.
2Manufacturing precision
If patient-specific implants are used, then the bone graft can be precisely tailored to the patient's anatomy, but the cost is high and requires long turnaround times
Solution Approach 1:
The implant is segmented into standardized cross-sectional portions that can be manufactured using conventional techniques rather than requiring expensive, time-consuming patient-specific manufacturing. The modular design allows precise anatomical fit to be achieved by assembling pre-manufactured modules without needing custom patient-specific implants.
Solution Approach 2:
The same set of modular cross-sectional portions can be used for multiple different patients and anatomical configurations. This universal design eliminates the need for expensive patient-specific manufacturing while maintaining the ability to achieve precise anatomical fit through selective assembly of the modular components.
3Productivity
If a modular system is used, then the bone graft can be assembled efficiently and cost-effectively, but the device complexity increases due to multiple components
Solution Approach 1:
The bone graft cage is segmented into multiple cross-sectional portions that can be manufactured independently using efficient processes. While this creates multiple components, the modular nature allows for standardized manufacturing and simplified assembly, improving productivity despite the increased number of parts.
Solution Approach 2:
Multiple cross-sectional portions are combined to form the complete bone graft cage structure. This merging of standardized modules creates a complete implant that can be assembled efficiently without requiring complex custom manufacturing, thus improving productivity while managing device complexity through standardization.
Data Source
AI summary
A graft cage includes cross-sectional portions and longitudinal members. Each portion includes base transverse members forming a cage base; a first arm including first arm transverse members; a second arm including second arm transverse members; base connecting struts, each base connecting strut extending between first one and second one of the base members; first arm connecting struts, each first arm connecting strut extending between a first one of the first members and a second one of the first members; and second arm connecting struts, each second arm connecting strut extending between first one and second one of the second members. The longitudinal members connect the portions to one another. Intersections of the portions with the longitudinal members forming pores in the first and second arms. The pores receive an arm tip of a further graft cage therein to interlock the cage with the further cage.