Patient-Specific 3D Printed Augment for Hip Implant Positioning
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Solution Overview
Problem
Accurate positioning of orthopaedic prosthetic components, such as the acetabular cup, is crucial for the longevity and functionality of hip joint replacements, but existing generic surgical instruments often lead to malpositioning, instability, and other complications due to their non-customized nature.
Innovation Solution
The method involves additively manufacturing a customized patient-specific augment for the acetabular shell component, which is designed to match the patient's bone contour, allowing for precise positioning and orientation during surgery, using techniques like Selective Laser Sintering or 3D printing, and integrating a porous coating for better bone integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If generic reusable orthopaedic surgical instruments are used, then device complexity is reduced and ease of manufacture is improved, but manufacturing precision and positioning accuracy deteriorate
Solution Approach 1:
Patient-specific anatomical data is captured and processed before surgery to create customized positioning instruments. The positive contour of the patient's bone is identified from medical images, and the augment is designed in advance with matching negative contours to ensure precise positioning during surgery.
Solution Approach 2:
The augment is created as a negative copy of the patient's positive bone contour. By adding an augment with a negative contour that matches the patient's positive contour, the instrument automatically positions itself accurately on the patient's anatomy without requiring complex adjustment mechanisms.
2Manufacturing precision
If customized patient-specific instruments are used, then manufacturing precision and positioning accuracy are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The augment serves multiple functions: it provides structural support to the acetabular shell, acts as a positioning guide by matching the patient's bone contour, and eliminates the need for separate alignment instruments. This multi-functionality reduces the number of different instruments needed despite the customization.
Solution Approach 2:
The augment's geometry is customized by changing parameters such as the negative contour shape to match the specific patient's anatomy. This parameter-based customization allows for precise positioning while using standardized manufacturing processes for additive fabrication.
3Manufacturing precision
If additional alignment guides and instruments are used, then positioning accuracy is improved, but operation time and procedural complexity increase
Solution Approach 1:
The positioning function is merged into the augment itself by incorporating the negative contour geometry directly onto the acetabular shell component. This eliminates the need for separate alignment guides and instruments, reducing the number of steps and tools required during surgery.
Solution Approach 2:
The augment performs self-positioning by automatically aligning with the patient's bone through its negative contour geometry. The instrument guides itself into the correct position without requiring additional alignment tools or complex surgical techniques.
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 enhances the accuracy and stability of prosthetic placement, reducing the need for additional alignment guides and instruments, thereby lowering costs and operation time while improving the longevity and functionality of the prosthetic joint.
Implementation Method 1
additively manufacturing an augment coupled to the outer wall of the manufactured acetabular shell component
Implementation Method 2
integrating a porous coating for better bone integration
Data Source
AI summary
An orthopaedic prosthetic component includes a manufactured acetabular shell component having an outer wall and an additively manufactured augment coupled to the outer wall. The augment includes an outer surface that defines a customized patient-specific negative contour shaped to conform to a positive contour of a patient's bone. A method for manufacturing the prosthetic component is also disclosed.