Modular Surgical Implant Assembly for Patient-Specific Bone Defects
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Solution Overview
Problem
Current solutions for patient-specific surgical implants for bone defects suffer from long turnaround times due to the challenges in predetermining bone void sizes and the complexity of custom fabrication.
Innovation Solution
A modular assembly of structurally identical scaffolds with complementary openings and pins/slots allows for customizable assembly during surgery, using bioresorbable materials like PCL-based composites, and can be manufactured via CT scans and 3D printing for precise fit and rapid production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If patient-specific customized implants are manufactured to match patient anatomy, then fitting and conformity to bone voids is improved, but production time increases
Solution Approach 1:
The implant is divided into multiple modular sections that can be manufactured separately and assembled during surgery. Each module can be produced using standardized processes while the overall configuration is customized to the patient's anatomy, reducing production time while maintaining fitting precision.
Solution Approach 2:
Standardized modular components are designed with universal interfaces that can be configured in multiple arrangements to match different bone void geometries. This allows a limited set of pre-manufactured modules to serve multiple patient-specific applications, reducing the need for lengthy custom fabrication.
2Ease of manufacture
If bone void size is predetermined for implant manufacturing, then production process is simplified, but accuracy in matching patient anatomy deteriorates
Solution Approach 1:
The implant system transitions from static predetermined sizes to dynamic configurable assemblies. Modular sections with adjustable configurations allow the final implant to be tailored to the actual bone void dimensions discovered during surgery, maintaining manufacturing simplicity while improving anatomical matching accuracy.
Solution Approach 2:
Standardized modules are prepared in advance with precise manufacturing, but the final configuration is determined closer to surgery based on actual bone void measurements. This preliminary preparation of standardized components maintains ease of manufacture while allowing final precision adjustment.
3Adaptability or versatility
If modular assembly with multiple sections is used, then customization and fit are improved, but device complexity increases
Solution Approach 1:
Modular sections are designed with nested or interlocking features that simplify assembly. The standardized interfaces and complementary geometries allow multiple sections to be assembled in a straightforward sequence during surgery, reducing the operational complexity despite the increased number of components.
Solution Approach 2:
The modular sections incorporate asymmetric complementary features (such as pins fitting into slots at specific angles) that guide proper assembly orientation. This asymmetric design ensures correct configuration while simplifying the assembly process through intuitive alignment, balancing customization capability with operational simplicity.
Data Source
AI summary
The present disclosure relates to surgical implants. In particular, the disclosure relates to a surgical implant modular assembly comprising at least a first scaffold and a second scaffold.