3D Implant Design System Using Optical Scanning
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Solution Overview
Problem
Current methods for generating custom surgical implants are costly, time-consuming, and do not account for individual anatomical asymmetries or allow for real-time visualization of the implant's external appearance, often requiring off-site fabrication and radiation from CT or MRI scans.
Innovation Solution
A method involving 3D imaging to simulate and generate virtual implants, allowing for on-site fabrication of custom implants using biocompatible materials, which can be injected or infused, enabling real-time visualization and customization based on individual anatomical features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If CT or MRI scans are used to generate custom implants, then anatomical accuracy is improved, but radiation exposure and cost increase
Solution Approach 1:
The patent uses optical 3D scanning to create a digital copy of the patient's external anatomy instead of using CT or MRI scans. This optical copying method achieves sufficient anatomical accuracy for implant design without exposing the patient to ionizing radiation, thereby resolving the contradiction between measurement precision and harmful factors.
2Manufacturing precision
If custom implants are fabricated off-site at laboratories, then customization accuracy is improved, but fabrication time and cost increase
Solution Approach 1:
The patent replaces traditional mechanical fabrication methods (injection molding at off-site laboratories) with additive manufacturing (3D printing). This substitution enables on-site fabrication of custom implants within hours while maintaining high customization accuracy, thereby reducing fabrication time and associated costs without sacrificing manufacturing precision.
3Productivity
If generic pre-fabricated implants are used, then cost and fabrication time are reduced, but anatomical fit and aesthetic outcome deteriorate
Solution Approach 1:
The patent applies local quality by creating implants with site-specific anatomical characteristics rather than using generic standardized designs. The 3D scanning and additive manufacturing process enables each implant to be precisely tailored to the patient's unique anatomy, achieving both high anatomical fit and reasonable fabrication efficiency through digital design and on-site printing.
4Strength
If traditional fabrication methods are used, then material strength is ensured, but visualization of surgical outcome and soft tissue prediction are lost
Solution Approach 1:
The patent performs preliminary visualization of the surgical outcome using the digital implant model before actual implantation. This allows surgeons and patients to preview and approve the expected aesthetic result and soft tissue modifications in advance, while the subsequent additive manufacturing process ensures the physical implant maintains required strength and structural integrity.
Data Source
AI summary
A method of designing, presenting, generating, and fabricating custom implants by obtaining a 3D image of a site to receive an implant, simulating volumetric changes of the site, generating a virtual 3D implant that effects the volumetric changes of the site, and fabricating a real 3D implant that includes the volumetric changes. A method of designing, presenting, generating, and implanting custom implants by obtaining a three-dimensional (3D) image of a site to receive an implant, simulating volumetric changes of the site, generating a virtual 3D implant that effects volumetric changes of the site, and injecting or infusing a gel or semi-solid implant into a patient to effect the volumetric changes. A method of implanting a custom implant in a patient. A method of correcting disfigurement in a patient. A method of replacing a disc in a patient's back. An implant fabricated by this method.