Monolithic Molded Navigation Arrays for Precise Surgical Tracking
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Solution Overview
Problem
Conventional multi-component navigation arrays in surgical navigation systems suffer from poor dimensional tolerances and user assembly errors, leading to inaccuracies in tracking surgical instruments and patient anatomy due to loosening under surgical forces.
Innovation Solution
The development of monolithic navigation arrays molded as a single piece, using injection molding to ensure precise geometric relationships between reflective marker regions, achieving tolerances of +/- 0.05 mm or better, eliminating mechanical interfaces for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-component navigation arrays are assembled from separate frame and marker components, then ease of manufacture and assembly is improved, but manufacturing precision and reliability deteriorate due to poor dimensional tolerances and assembly errors
Solution Approach 1:
The patent merges the frame and marker components into a single monolithic navigation array structure. This eliminates the separate components that required assembly, thereby removing assembly errors and poor dimensional tolerances while maintaining manufacturability through single-piece molding processes
2Ease of manufacture
If multi-component navigation arrays are used, then ease of manufacture is improved, but reliability deteriorates due to loosening under surgical forces
Solution Approach 1:
The monolithic structure combines all navigation array components into one integrated piece, eliminating mechanical interfaces that could loosen under surgical forces such as vibration. This single-piece construction ensures structural stability and reliability throughout the surgical procedure
3Manufacturing precision
If monolithic navigation arrays are molded as a single piece, then manufacturing precision is improved with tolerances of +/- 0.05 mm or better, but device complexity increases
Solution Approach 1:
The patent combines multiple components into a single monolithic structure that can be molded in one operation. This approach achieves high geometric accuracy of +/- 0.05 mm or better while actually simplifying the manufacturing process by eliminating multiple assembly steps, thereby reducing rather than increasing overall device complexity
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 monolithic navigation arrays provide high accuracy and consistency, ensuring precise tracking of surgical instruments and patient anatomy with reduced errors, suitable for robotic surgical systems and various surgical procedures.
Implementation Method 1
optical navigation or tracking systems may utilize stereoscopic sensors to detect infra-red (IR) light reflected or emitted from one or more optical markers
Data Source
AI summary
Systems, methods, and devices are described for high accuracy molded navigation arrays. In a first embodiment, a navigation array is formed by molding, as a single component, an array having a plurality of marker regions. The marker regions include a reflective layer disposed thereon. In other embodiments, a navigation array is formed by molding over a frame having a plurality of marker elements. In still other embodiments, a navigation array is formed by molding over individual marker elements. In certain embodiments, a navigation array is formed by molding a frame with a plurality of voids and subsequently molding marker elements into each void where the marker elements include a reflective layer disposed thereon. In some embodiments, a navigation array is formed by molding a plurality of marker elements on a frame and disposing a reflective layer on the marker elements.