Monolithic Fusion Cage with Frangible Fixation and Insertion
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Solution Overview
Problem
Surgical implant systems often require multiple components, leading to challenges in organization, sterilization, and accuracy during procedures, increasing manufacturing costs and inventory needs.
Innovation Solution
A surgical implant system comprising a single monolithic structure that includes an implant, a fixation member, and an insertion instrument, connected via frangible connections that can be broken using torque or force, manufactured through 3D printing or additive layer manufacturing, allowing for a streamlined and efficient implantation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components (implant, fixation members, instruments) are used, then each component can be optimized for its specific function, but the number of components increases leading to organization challenges, sterilization complexity, and handling difficulties
Solution Approach 1:
The patent combines the implant body, fixation members (screws/anchors), and insertion instruments into a single monolithic structure that is 3D printed as one integrated component. This merging eliminates the need to handle multiple separate parts, simplifies sterilization to a single process, and ensures precise alignment during surgery while maintaining all necessary functions through the integrated design
Solution Approach 2:
The monolithic structure serves multiple functions simultaneously: the main body provides implantation and spacing, integrated fixation members provide anchoring to bone, and integrated instruments provide insertion and positioning capabilities. This multi-functionality is achieved within a single component rather than requiring separate optimized parts for each function
2Ease of manufacture
If multiple separate components are used, then each component can be manufactured independently, but manufacturing costs and inventory requirements increase
Solution Approach 1:
By combining all components into one monolithic structure, the patent reduces manufacturing from producing multiple separate items to producing a single item. This reduces raw material consumption, eliminates assembly costs, reduces quality control steps for multiple components, and simplifies inventory management to tracking a single product rather than multiple components
Solution Approach 2:
The patent utilizes 3D printing technology which changes the manufacturing parameter from traditional subtractive or assembly-based methods to additive manufacturing. This enables complex integrated geometries to be produced efficiently, reduces material waste compared to traditional manufacturing of multiple parts, and allows for customization without additional tooling costs
3Ease of operation
If multiple separate components are used, then assembly flexibility is maintained, but accuracy and efficiency in handling and placing components during surgery decreases
Solution Approach 1:
The integration of the implant and instruments into one monolithic structure ensures that the relative positions and orientations of all components are precisely fixed during manufacturing. This eliminates positioning errors that can occur during manual assembly of separate components, ensuring accurate placement during surgery while maintaining the flexibility needed for surgical manipulation through the integrated design
Data Source
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AI summary
A surgical implant system includes an implant (110, 210, 310, 410) and a fixation member (125, 245, 325, 425) for securing the implant to tissue. The implant and the fixation member together comprise a single monolithic structure. The implant includes an insertion instrument (130, 230, 330). The implant, the fixation member, and the insertion instrument together comprise a single monolithic structure and are constructed from a single material. The implant is monolithically connected to the fixation member at a first frangible connection and is monolithically connected to the insertion instrument at a second frangible connection. Each of the frangible connections can be broken when force is applied.