Non-Polygonal Porous Bone Implants via Layer Offset
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current bone implants with polygonal porous structures lack the biocompatibility and bone ingrowth advantages of non-polygonal structures, which are more similar to natural bone, leading to suboptimal biological fixation and integration.
Innovation Solution
The development of a porous implantable structure with substantially regularly arranged elementary cells forming non-polygonal shapes, where each layer is offset with respect to adjacent layers, creating interconnected pores that mimic the structure of natural bone, such as trabecular bone, using additive manufacturing techniques like Selective Laser Melting or Electron Beam Melting with biocompatible materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polygonal porous structures are used in bone implants, then manufacturing precision and structural regularity are improved, but biocompatibility and bone ingrowth are worsened
Solution Approach 1:
The patent applies curved, non-polygonal geometries to the porous structure elements, replacing sharp angular shapes with rounded contours that more closely resemble natural bone architecture. This curvature modification improves biocompatibility while maintaining the periodic structural regularity needed for manufacturing precision through additive manufacturing processes.
2Reliability
If non-polygonal porous structures are used to mimic natural bone, then biocompatibility and bone ingrowth are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the porous structure into repeating elementary cells with non-polygonal geometries, organized in periodic patterns across multiple layers. This segmentation approach allows complex biocompatible shapes to be manufactured through additive processes while maintaining overall structural order and reducing manufacturing complexity compared to entirely irregular designs.
Solution Approach 2:
The patent modifies geometric parameters of the porous structure, specifically changing from polygonal to non-polygonal shapes with controlled curvature radii and size ratios. These parameter changes enable better bone ingrowth while the periodic arrangement maintains manufacturability through standard additive manufacturing protocols.
3Reliability
If layers are shifted and rotated relative to each other, then biocompatibility is improved, but structural symmetry is reduced
Solution Approach 1:
The patent introduces asymmetric arrangements by shifting and rotating adjacent layers relative to each other, creating a staggered pattern that disrupts perfect symmetry. This asymmetry enhances biocompatibility by creating more varied pore configurations that better mimic natural bone, while the periodic repetition maintains sufficient structural stability.
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
This approach enhances biological fixation and bone ingrowth by creating a structure that is more similar to natural bone, improving the integration and stability of implants while maintaining mechanical strength and load-bearing capabilities.
Implementation Method 1
Porous structures can be formed by additive manufacturing methods like Selective Laser Melting (SLM) or Electron Beam Melting (EBM). These methods allow for making porous metal products by building layers and solidifying material from powder to solid by means of a melting process.
Implementation Method 2
Porous structures can be formed by additive manufacturing methods like Selective Laser Melting (SLM) or Electron Beam Melting (EBM). These methods allow for making porous metal products by building layers and solidifying material from powder to solid by means of a melting process.
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The disclosure includes a porous implantable structure, that includes substantially regularly arranged elementary cells, wherein the elementary cells include interior spaces that form a plurality of interconnected pores, the elementary cells include basic elements arranged in layers, wherein the basic elements are configured to form a non-polygonal shape of each of the plurality of interconnected pores, wherein each layer is offset with respect to an adjacent layer.