Patient-Matched Surgical Instruments with Discrete Contact Portions
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Solution Overview
Problem
Conventional patient-matched surgical instruments for knee arthroplasty face challenges such as inaccurate fit due to minor errors in segmentation, smooth surfaces leading to slippage, and improper seating with anatomical irregularities, which can result in poor fit and stability issues.
Innovation Solution
The development of patient-matched surgical instruments with discrete, non-uniform anatomy contacting portions and recessed areas, designed using 3D computer models to match specific patient anatomy, providing improved fit and stability through customized geometry and distribution of contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If smooth continuous anatomy-contacting surfaces are used to conform to patient anatomy, then the instrument can match patient-specific geometry, but the smooth surfaces cause slippage and instability during surgery
Solution Approach 1:
The patent applies local quality by transitioning from uniformly smooth contact surfaces to a heterogeneous surface structure with discrete contact portions and recessed areas. The discrete contact portions provide localized high-friction zones that prevent slippage, while recessed areas accommodate anatomical irregularities. This local differentiation resolves the contradiction by maintaining anatomy match accuracy through customization while improving stability through strategic friction enhancement at specific contact points.
2Area of stationary object
If large continuous anatomy-contacting surfaces are used to ensure comprehensive anatomical coverage, then complete anatomical representation is achieved, but minor segmentation errors cause poor fit and instrument rejection
Solution Approach 1:
The patent applies segmentation by dividing the continuous anatomy-contacting surface into multiple discrete contact portions separated by recessed areas. This segmentation reduces the impact of segmentation errors because individual discrete portions can tolerate local inaccuracies without compromising overall fit. The recessed areas provide tolerance zones that accommodate variations, allowing the instrument to maintain reliable fit even with minor segmentation deviations while still achieving comprehensive anatomical coverage through the distributed contact portions.
3Manufacturing precision
If highly conforming patient-matched instruments are used to achieve precise anatomical fit, then patient-specific geometry is matched, but improper seating occurs with anatomical irregularities such as osteophytes and tumors
Solution Approach 1:
The patent applies inversion by reversing the conventional approach of making the contact surface fully conforming to anatomy. Instead, it creates a partially conforming surface with discrete contact portions that selectively engage anatomical landmarks while recessed areas deliberately exclude irregularities like osteophytes and tumors. This inverted strategy achieves precise anatomical fit at critical contact points while improving seating reliability by allowing anatomical irregularities to occupy the recessed non-contact zones.
Data Source
AI summary
Patient-matched surgical instruments and associated methods having an anatomy facing side including several discrete, physically separate anatomy contacting portions configured to match the anatomy of a particular patient and including one or more of non-uniform in distribution, non-uniform in shape and non-uniform in surface area.