Disposable Orthopedic Prosthesis Mold Reinforcement
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Solution Overview
Problem
Existing methods for creating temporary orthopedic prostheses are prone to overfilling, spillage, deformation, and require extensive surgical time due to the need for custom molds and manual preparation, which can lead to soft tissue damage and complicate revision surgeries.
Innovation Solution
The development of orthopedic prosthesis molds with reinforced housings and connecting elements that prevent deformation, include injection ports with caps for precise filling, vent ports for air escape, and a connecting element for easy separation, providing a range of sizes and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual mold creation methods are used, then customization to patient anatomy is achieved, but surgical time increases and soft tissue damage occurs
Solution Approach 1:
The mold is pre-formed and sterilized before surgery, eliminating the need for intraoperative mold creation. The mold is ready for immediate use with the articulating component, significantly reducing surgical time and avoiding soft tissue damage that would result from extended positioning requirements
Solution Approach 2:
The mold creates an accurate copy or impression of the patient's specific bone anatomy and the articulating component. This precise copying allows for perfect fit and function while enabling rapid manufacturing through digital or physical replication processes, eliminating time-consuming manual formation
2Manufacturing precision
If disposable molds with reinforcement elements are used, then deformation is prevented, but manufacturing complexity increases
Solution Approach 1:
The mold is constructed from composite materials combining rigid support structures with flexible, biocompatible outer layers. This composite construction provides the necessary reinforcement to prevent deformation under articulating component pressure while maintaining the flexibility needed for precise anatomical conformability
Solution Approach 2:
The mold is divided into modular segments or layers, with reinforcement elements strategically positioned at critical stress points. This segmentation allows for targeted reinforcement without unnecessary complexity throughout the entire structure, optimizing the balance between deformation resistance and manufacturing simplicity
3Manufacturing precision
If injection ports with caps are used, then overfilling is prevented, but device complexity increases
Solution Approach 1:
The injection port cap is designed to automatically engage and seal the injection port when the mold is properly assembled. This self-service mechanism prevents overfilling and material spillage without requiring complex external control systems or additional manual intervention, thereby limiting the increase in device complexity
Data Source
AI summary
An orthopedic prosthesis mold, including a first housing defining a first cavity therein shaped to form a portion of an orthopedic prosthesis; a second housing coupled to the first housing, the second housing defining a second cavity therein shaped to form a portion of an orthopedic prosthesis; and a reinforcement element attached to at least one of the first or second housings, the reinforcement element resisting deformation of the first and second housings. The reinforcement element may include a member exterior to the first and second cavities, the member spanning across a substantial width of the prosthesis mold.