Patient-Specific Orthopaedic Instruments via 3D Printing

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Solution Overview

Problem

Current orthopaedic surgical instruments are generic and reusable, which can lead to inefficiencies and inaccuracies in joint replacement surgeries, as they do not account for the unique anatomy of individual patients, potentially resulting in suboptimal surgical outcomes.

Innovation Solution

Customized patient-specific orthopaedic surgical instruments are created using 3D modeling and 3D printing techniques, where a patient's bone is scanned to generate a precise model, allowing for the fabrication of instruments with tailored features such as negative contours and guide slots that match the patient's anatomy, enabling precise alignment and resection during surgery.

Engineering Contradictions & Design Principles

VSEngineering 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 measurement precision deteriorate due to inability to account for unique patient anatomy

Engineering Contradiction:

Improveinstrument fit to patient boneVSAvoidcustomized instrument design

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Patient-specific instruments are designed and manufactured before surgery based on pre-operative imaging data (CT or MRI scans). The instruments incorporate patient-specific anatomical surface contours that are determined and fabricated in advance, allowing precise fit to the patient's unique bone geometry without requiring complex intraoperative adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patient-specific instruments include a bone-contacting surface that is a negative impression or copy of the patient's actual bone surface geometry. This copying approach, achieved through reverse engineering from imaging data, enables the instrument to precisely match the patient's unique anatomy, improving measurement and manufacturing precision while managing design complexity through digital modeling.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If customized patient-specific orthopaedic surgical instruments are manufactured using 3D printing, then manufacturing precision and adaptability are improved, but production time and complexity increase

Engineering Contradiction:

Improveinstrument customization to patient anatomyVSAvoidinstrument fabrication time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The invention utilizes additive manufacturing (3D printing) technology to fabricate patient-specific instruments directly from digital models. This parameter change in manufacturing methodology allows complex customized geometries to be produced efficiently without traditional subtractive manufacturing constraints, reducing fabrication time while maintaining high adaptability to patient-specific anatomy.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

All customization and design work is completed in the pre-operative planning phase using imaging data and computer-aided design software. The instruments are manufactured before surgery, eliminating any time loss during the surgical procedure itself. The entire customization process is consolidated into the planning phase, making the actual surgery more efficient.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If generic surgical instruments are used, then ease of operation is maintained through standardization, but measurement precision deteriorates due to lack of patient-specific anatomical matching

Engineering Contradiction:

Improveanatomical alignment accuracyVSAvoidsurgical procedure complexity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The optimal anatomical alignment and instrument positioning are determined during pre-operative planning. The patient-specific instruments are designed with built-in alignment features and anatomical matching surfaces that guide the surgeon through the procedure, reducing intraoperative decision-making complexity while achieving high measurement precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patient-specific bone-contacting surfaces enable the instruments to self-align and self-position on the patient's unique anatomy. The negative contour of the instrument surface automatically matches the positive contour of the patient's bone, providing inherent alignment without requiring complex adjustment procedures during surgery.

Inventive Principle:

Principle #25Self-service

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 reduces the need for intra-operative guesswork, improves surgical precision, minimizes tissue damage, and enhances the fit of prosthetic components, leading to better surgical outcomes and reduced recovery times.

Implementation Method 1

fabricating the customized patient-specific orthopaedic surgical instrument from metallic material based on the customized patient-specific surgical instrument model

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS11653933B2Method of designing and manufacturing low-profile customized patient-specific orthopaedic surgical instruments

Publication Date: 2023.05.23 DEPUY SYNTHES PROD INC

AI summary

Methods of designing and manufacturing a number of low-profile metallic customized, patient-specific orthopaedic surgical instruments are disclosed.