Patient-Specific Implant Design Using a Standard Core and Custom Periphery

Solution Overview

Problem

Existing methods for designing patient-specific implants are costly and time-consuming due to the need for custom implants tailored to each patient's unique bone and joint shape, requiring additional time and expertise, and existing tools are not adapted for efficient customization.

Innovation Solution

A method involving obtaining a 3D model of a patient's bone, virtually cutting it to define a resected surface, selecting a standard implant with a smaller bone-contacting surface, and designing a custom peripheral portion to extend from the standard implant, aligning it with the resected bone surface to create a patient-specific implant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If custom implants are designed for each patient to fit unique bone and joint shape, then the implant precision and patient-specific fit are improved, but the design time and manufacturing cost increase significantly

Engineering Contradiction:

Improveimplant fit precisionVSAvoiddesign time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The implant is divided into two distinct parts: a standardized base implant and a custom peripheral portion. The base implant uses standard sizes and designs that can be manufactured efficiently, while only the peripheral portion is customized to match the patient's specific bone geometry. This segmentation allows the majority of the implant to be produced through standardized processes, reducing overall design time and cost while maintaining patient-specific precision where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Customization is applied locally only to the peripheral portion of the implant that contacts the patient's bone, while the central base portion remains standardized. This allows the implant to have standard properties in the bulk while having customized properties only at the interface with the patient's bone, optimizing both manufacturing efficiency and patient-specific fit.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If custom implants are designed for each patient to fit unique bone and joint shape, then the implant precision and patient-specific fit are improved, but the manufacturing cost increases

Engineering Contradiction:

Improveimplant fit precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The implant is divided into two distinct parts: a standardized base implant and a custom peripheral portion. The base implant uses standard sizes and designs that can be manufactured efficiently, while only the peripheral portion is customized to match the patient's specific bone geometry. This segmentation allows the majority of the implant to be produced through standardized processes, reducing overall design time and cost while maintaining patient-specific precision where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized base implant serves as a template or copy that can be manufactured repeatedly using the same process. Only the peripheral portion requires custom design and manufacturing for each patient. This copying approach allows for economies of scale in producing the base implant while maintaining patient-specific customization at the critical interface.

Inventive Principle:

Principle #26Copying

3Productivity

If standard implants are used for all patients, then the manufacturing cost and time are reduced, but the precision and adaptability to individual patient anatomy deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidpatient-specific adaptability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The implant is divided into two distinct parts: a standardized base implant and a custom peripheral portion. The base implant uses standard sizes and designs that can be manufactured efficiently, while only the peripheral portion is customized to match the patient's specific bone geometry. This segmentation allows the majority of the implant to be produced through standardized processes, reducing overall design time and cost while maintaining patient-specific precision where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Customization is applied locally only to the peripheral portion of the implant that contacts the patient's bone, while the central base portion remains standardized. This allows the implant to have standard properties in the bulk while having customized properties only at the interface with the patient's bone, optimizing both manufacturing efficiency and patient-specific fit.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12472068B2Method for designing a patient-specific implant and patient-specific implant

Publication Date: 2025.11.18 LAB BODYCAD

AI summary

A method for designing a patient-specific implant is provided. The method includes the steps of obtaining a 3D model of at least an articulation portion of a patient's bone, virtually cutting the articulation portion of the 3D model of the patient's bone for defining a resected bone surface having a resected surface area, selecting an implant from a library of standard implants based on the 3D model, virtually engaging the bone-contacting surface of the selected implant with the resected bone surface, designing an implant peripheral portion configured to extend from the selected implant and conform to the 3D model and virtually combining the selected implant and designed implant perimeter to create a 3D model of the patient-specific implant.