Custom Orthopedic Implant Manufacturing via Laser Sintering

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Solution Overview

Problem

Traditional orthopedic implant manufacturing methods often result in sub-optimal fits due to standard sizes, requiring invasive procedures and leading to bone loss and frequent prosthesis replacement, while custom-made implants are costly and time-consuming to produce.

Innovation Solution

The method involves obtaining a three-dimensional image of a patient's joint to modify a standard blank implant by adding or removing material using techniques like laser sintering and electron beam melting, allowing for precise customization of implant size and shape to match the patient's anatomy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If standard off-the-shelf implants are used, then manufacturing cost and time are reduced, but implant fit and patient outcome deteriorate

Engineering Contradiction:

Improvemanufacturing cost and timeVSAvoidimplant fit to patient anatomy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent performs preliminary actions by obtaining patient-specific imaging data and creating a customized implant design before manufacturing. This preliminary customization step enables precise anatomical matching while using efficient manufacturing processes, resolving the contradiction between standardization benefits and customization needs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes key parameters by transitioning from fixed standard implant sizes to variable patient-specific dimensions. Through imaging-based measurement and computational design, the implant parameters (size, shape, geometry) are customized to match individual patient anatomy, achieving both precision fit and manufacturing efficiency.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If custom-made patient-specific implants are produced, then implant fit and patient outcome are improved, but manufacturing cost and time increase

Engineering Contradiction:

Improveimplant fit to patient anatomyVSAvoidmanufacturing cost and time

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies universality by using a standardized manufacturing platform and process flow that can handle multiple patient-specific cases. The same imaging, design, and manufacturing system serves various implant types and patient anatomies, reducing per-unit cost and time while maintaining customization benefits.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent employs accelerated manufacturing through advanced imaging technologies and computational design algorithms that rapidly process patient data into manufacturing-ready designs. This acceleration reduces the time and cost overhead of customization by streamlining the data-to-implant workflow.

Inventive Principle:

Principle #38Strong oxidants (Accelerated oxidation)

3Adaptability or versatility

If invasive surgical procedures are used to accommodate standard implants, then implant availability is improved, but bone loss and surgical trauma increase

Engineering Contradiction:

Improveimplant availabilityVSAvoidbone loss and surgical trauma

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating implants with patient-specific geometry that precisely matches the local anatomical conditions at the implantation site. This localized customization eliminates the need for invasive bone removal or tissue sacrifice, as the implant is designed to fit the existing anatomy rather than requiring the anatomy to be modified to fit the implant.

Inventive Principle:

Principle #3Local quality

4Duration of action of stationary object

If repeated prosthesis replacement surgeries are performed, then implant longevity is improved, but cumulative surgical trauma and bone loss increase

Engineering Contradiction:

Improveimplant longevityVSAvoidcumulative surgical trauma and bone loss

Core Design Contradiction:

Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent performs preliminary action by creating a precisely fitted custom implant before implantation, ensuring optimal initial placement and load distribution. This preliminary precision reduces the risk of premature failure and the need for replacement surgeries, thereby improving long-term implant longevity while minimizing cumulative surgical trauma.

Inventive Principle:

Principle #10Preliminary action

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 enables the creation of patient-specific implants that provide a better fit, reduce surgical invasiveness, and are more cost-effective and timely to produce, maintaining implant strength and longevity.

Implementation Method 1

adding material to the blank may include laser sintering

Methodology Applied

Scientific EffectLaser sintering: Selective Laser Sintering

Implementation Method 2

adding material to the blank may include electron beam melting

Methodology Applied

Scientific EffectElectron beam melting: Electron Beam

Data Source

PatentUS9517134B2Implant device and method for manufacture

Publication Date: 2016.12.13 CONFORMIS INC

AI summary

Disclosed are systems, devices and methods for optimizing the manufacture and/or production of patient-specific orthopedic implants. The methods include obtaining image data of a patient, selecting a blank implant to be optimized for the patient, and modifying the blank implant utilizing techniques disclosed herein to alter specific features of the implant to conform to the patient's anatomy.