Modular Orthopaedic Spacer Mould with Vent Conduits
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Solution Overview
Problem
Existing orthopaedic temporary spacers face limitations in mechanical resistance, unpredictability of antibiotic release, and poor flexibility, leading to the need for various sizes and shapes during surgical operations.
Innovation Solution
A modular forming mould for orthopaedic spacers made of medical cement, comprising coupled moulding elements with a thermoplastic copolymer-based material and semi-rigid polypropylene, equipped with vent conduits for air bubble prevention and antibiotic distribution, allowing for customizable shapes and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual modelling and compacting of medical cement is performed by specialist personnel, then the spacer can be created directly in the operating theatre with flexibility in shape, but the mechanical resistance is low and antibiotic release is unpredictable
Solution Approach 1:
The mould is divided into two separate moulding shells (first and second shells) that can be coupled together. This segmentation allows the cement to be compacted more effectively between the shells, improving mechanical resistance while maintaining the ability to create various shapes by selecting different shell combinations.
Solution Approach 2:
The set of moulding shells is designed to be modular, where different combinations of shells can create different spacer shapes and sizes. This universal system allows the same basic components to serve multiple functions, providing both mechanical strength through proper compaction and flexibility in adapting to different anatomical requirements.
2Strength
If preformed spacers are made directly in the factory, then the spacer has reasonable mechanical resistance and controlled antibiotic release, but use flexibility is poor and multiple sizes and shapes are required
Solution Approach 1:
The moulding system is segmented into multiple interchangeable shells that can be combined in different ways. This allows a single modular system to replace multiple preformed spacers of different sizes and shapes, improving use flexibility while maintaining factory-produced quality standards for mechanical resistance and antibiotic release.
Solution Approach 2:
The modular shell system provides dynamic adaptability, allowing the surgical team to select and combine appropriate shells based on the specific anatomical requirements during the operation. This dynamic configuration capability eliminates the need for multiple preformed spacers while ensuring optimal mechanical properties through consistent factory manufacturing.
3Ease of operation
If moulding shells are made of flexible silicone material, then the closing operations are facilitated and spacer extraction is easier, but the compacting efficacy and sealing of the mould shells is reduced
Solution Approach 1:
Different regions of the moulding system have different material properties optimized for their specific functions. The moulding shells incorporate materials with appropriate flexibility for ease of operation in certain areas, while other regions provide sufficient rigidity for effective compaction and sealing, achieving both ease of operation and mechanical efficacy.
Solution Approach 2:
The moulding shells are constructed using composite materials that combine the advantages of flexible materials (ease of closing and extraction) with rigid materials (compacting efficacy and sealing). This composite construction resolves the contradiction by integrating multiple material properties into a single functional component.
Data Source
Figure 1
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Figure 3A
AI summary
A mould (1) and accessories thereof for the forming of an orthopaedic spacer made of medical cement, defining a moulding cavity (2) delimited by a moulding surface (3) configured to impart a pre-established shape to the medical cement and to create the orthopaedic spacer, wherein at least one sector (6) of the forming mould (1) defining at least one portion of the moulding surface (3) is made with a thermoplastic copolymer based material.