Osteosynthesis Implant Metal-Plastic Composite Fabrication
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Solution Overview
Problem
Current methods for producing implants for osteosynthesis are labor-intensive and time-consuming, leading to high production costs and complex quality control processes, with limited potential for reducing workload and costs despite optimization over the last decade.
Innovation Solution
A method combining mass production techniques like extrusion, stamping, or casting for the load-bearing metal component with overmolding or impact extrusion using biocompatible plastics to achieve anatomical shape compatibility, allowing for a cost-effective and high-quality implant production by integrating a metal section with a plastic section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining processes are used to produce implants with anatomical shape and load-bearing function, then the implant quality and functionality are ensured, but the production time and labor intensity increase significantly
Solution Approach 1:
The implant is divided into two functional sections: a load-bearing metal section produced by efficient mass production methods, and an anatomically shaped plastic section produced by injection molding. This segmentation allows each material to be optimized for its specific function while using appropriate manufacturing processes for each.
Solution Approach 2:
The patent creates a composite implant structure combining metal and plastic materials. The metal provides load-bearing capacity while the plastic provides anatomical conformity. This composite approach enables the use of different manufacturing processes optimized for each material type, resolving the contradiction between precision and productivity.
2Productivity
If pure plastic injection molding is used to produce implants, then production costs and time are reduced, but the structural strength and load-bearing capacity are insufficient
Solution Approach 1:
The implant is divided into two functional sections: a load-bearing metal section produced by efficient mass production methods, and an anatomically shaped plastic section produced by injection molding. This segmentation allows each material to be optimized for its specific function while using appropriate manufacturing processes for each.
Solution Approach 2:
The patent creates a composite implant structure combining metal and plastic materials. The metal provides load-bearing capacity while the plastic provides anatomical conformity. This composite approach enables the use of different manufacturing processes optimized for each material type, resolving the contradiction between precision and productivity.
3Strength
If metal implants with anatomical shape are produced through machining, then load-bearing strength is ensured, but production complexity and costs increase
Solution Approach 1:
The implant is divided into two functional sections: a load-bearing metal section produced by efficient mass production methods, and an anatomically shaped plastic section produced by injection molding. This segmentation allows each material to be optimized for its specific function while using appropriate manufacturing processes for each.
Solution Approach 2:
The patent creates a composite implant structure combining metal and plastic materials. The metal provides load-bearing capacity while the plastic provides anatomical conformity. This composite approach enables the use of different manufacturing processes optimized for each material type, resolving the contradiction between precision and productivity.
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 significantly reduces production time and costs while maintaining high quality and load-bearing functionality, ensuring both anatomical fit and structural integrity, with the option for partial or complete encapsulation of the metal component.
Implementation Method 1
the sheathing can be done by impact extrusion
Implementation Method 2
the sheathing can be done by impact extrusion
Data Source
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AI summary
The invention relates to a method for producing an osteosynthetic implant, comprising the steps of producing a load-bearing metal component and coating the load-bearing component with a biocompatible material.