Orthopedic Connecting Element With Load-Tuned Wall Thickness

Solution Overview

Problem

Existing methods for producing connecting elements for orthopedic devices require excessive material thickness to compensate for mechanical loads, leading to increased costs, weight, and difficulty in forming by orthopedic technicians.

Innovation Solution

A method involving 3D scanning of body parts and components to determine target positions and orientations, followed by modeling and additive manufacturing to produce customized connecting elements, reducing material thickness and production steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the connecting element is produced with greater material thickness to compensate for mechanical loads, then the stability and strength are improved, but the amount of material required increases, leading to increased costs, weight, and difficulty in forming processing

Engineering Contradiction:

Improvestability of connecting elementVSAvoidamount of material required

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The connecting element features non-uniform wall thickness distribution, with thicker sections at locations subject to high mechanical loads and thinner sections where loads are lower. This local variation in quality allows the element to achieve necessary strength at critical points while reducing overall material consumption and forming difficulty.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The method employs 3D scanning and computational modeling to precisely determine the optimal wall thickness distribution based on actual mechanical loads. By changing the thickness parameter spatially rather than uniformly, the design achieves strength optimization without excessive material usage.

Inventive Principle:

Principle #35Parameter changes

2Strength

If the connecting element is produced with greater material thickness to compensate for mechanical loads, then the strength is improved, but the weight increases

Engineering Contradiction:

Improvestrength of connecting elementVSAvoidweight of connecting element

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The connecting element features non-uniform wall thickness distribution, with thicker sections at locations subject to high mechanical loads and thinner sections where loads are lower. This local variation in quality allows the element to achieve necessary strength at critical points while reducing overall material consumption and forming difficulty.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The method employs 3D scanning and computational modeling to precisely determine the optimal wall thickness distribution based on actual mechanical loads. By changing the thickness parameter spatially rather than uniformly, the design achieves strength optimization without excessive material usage.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If the connecting element is produced with greater material thickness to compensate for mechanical loads, then the stability is improved, but the ease of manufacture deteriorates

Engineering Contradiction:

Improvestability of connecting elementVSAvoidease of forming by orthopedic technician

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The connecting element features non-uniform wall thickness distribution, with thicker sections at locations subject to high mechanical loads and thinner sections where loads are lower. This local variation in quality allows the element to achieve necessary strength at critical points while reducing overall material consumption and forming difficulty.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The method employs 3D scanning and computational modeling to precisely determine the optimal wall thickness distribution based on actual mechanical loads. By changing the thickness parameter spatially rather than uniformly, the design achieves strength optimization without excessive material usage.

Inventive Principle:

Principle #35Parameter changes

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

Reduces material usage and production time while maintaining stability and custom fit, enhancing the efficiency and cost-effectiveness of orthopedic device production.

Implementation Method 1

Capturing three-dimensional scan data of at least one part of the body part and/or at least one part of each of the two components using a scanner

Methodology Applied

Scientific Effect3D scanning: Photogrammetry

Data Source

PatentUS12544247B2Method for producing a connecting element

Publication Date: 2026.02.10 OTTOBOCK SE & CO KGAA

AI summary

The invention relates to a method for producing a connecting element for connecting two components of an orthopedic device for a body part, wherein the method includes capturing three-dimensional scan data of at least one part of the body part by means of a scanner, determining a target position and/or target orientation of the connecting element relative to the body part from the scan data, modelling the connecting element using the scan data, the target position and/or the target orientation and information on the components to be connected, and producing the modelled connecting element.