Additive Manufacturing Orthopedic Connecting Elements
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Solution Overview
Problem
Existing methods for producing connecting elements for orthopedic devices often require reshaping of materials, leading to reduced stability, increased material thickness, and higher costs due to unnecessary material usage and complex manufacturing processes.
Innovation Solution
A method involving 3D scanning of body parts to acquire data for modeling and manufacturing connecting elements, allowing for precise adaptation and reduced material thickness, using additive manufacturing processes and fiber reinforcement for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the metal joint leg is bent while cold to achieve the desired shape, then the connecting element can be adapted to individual needs, but a high level of mechanical stress is placed on the material, reducing its stability
Solution Approach 1:
The connecting element is pre-formed with the desired shape and dimensions using additive manufacturing technology before assembly. This preliminary action eliminates the need for cold bending during assembly, thereby avoiding mechanical stress and material instability while maintaining individual adaptability through digital modeling and 3D printing processes
2Stability of the object's composition
If the connecting element is manufactured with a greater material thickness to compensate for mechanical stress, then stability is improved, but material requirements and cost increase
Solution Approach 1:
The invention changes the manufacturing parameters from traditional subtractive or forming methods to additive manufacturing with optimized digital models. This allows precise control of material deposition, creating connecting elements with optimal thickness that maintain stability without excessive material usage, thereby reducing both material requirements and costs
3Reliability
If the connecting element is manufactured with a greater material thickness to ensure stability, then reliability is improved, but the weight of the connecting element increases
Solution Approach 1:
Additive manufacturing enables precise control of material deposition parameters, allowing the connecting element to be manufactured with optimal thickness that ensures reliability while minimizing weight. The digital modeling process allows for simulation and optimization of material distribution to achieve the lightest possible structure that meets strength requirements
4Ease of manufacture
If traditional manufacturing methods are used for the connecting element, then the process is simpler, but manufacturing time and cost increase due to reshaping requirements
Solution Approach 1:
The connecting element is pre-formed with the exact desired shape using additive manufacturing technology before assembly. This preliminary action eliminates subsequent reshaping operations by the orthopedic technician, reducing manufacturing time and complexity while maintaining ease of manufacture through digital design and automated 3D printing processes
Data Source
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AI summary
The invention relates to a method for manufacturing a connecting element (8) for connecting two components (4, 6) of an orthopaedic device (2) for a body part, wherein the method comprises the following steps: capturing 3-dimensional scan data (28) of at least a part of each of the two components (4, 6) using a scanner (22), determining a target position and/or a target orientation of the connecting element (8) relative to the components (4, 6) from the scan data (28), modeling the connecting element (8) using the scan data (28), the target position and/or the target orientation and information about the components (4, 6) to be connected, and manufacturing the modeled connecting element (8).