Customized Pectus Carinatum Chest Bar with Modular Strap Fixation
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Solution Overview
Problem
Current treatments for pectus carinatum, including surgically implanted orthotic braces and minimally invasive surgery, face challenges with brace wear duration and complexity of implant fixation, particularly for severe cases.
Innovation Solution
A customized pectus carinatum sternal pull-back device featuring a subcutaneous chest bar with tailored dimensions and securing straps, utilizing 3D digital imaging and 3D printing for precise fit, along with a simplified fixation system using titanium or surgical steel implants and polymer plastic straps, to correct the deformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current minimally invasive surgery approaches are used for pectus carinatum, then surgical effectiveness is improved, but implant fixation complexity increases
Solution Approach 1:
The fixation system is divided into separate modular components: a chest bar implant and detachable securing straps. This segmentation allows the complex fixation function to be distributed across simpler, more manageable parts that can be independently manufactured and assembled, reducing overall system complexity while maintaining surgical effectiveness.
Solution Approach 2:
The securing strap acts as an intermediary element between the chest bar implant and the ribs. Instead of directly anchoring the implant to the ribs (which would require complex fixation mechanisms), the strap serves as a mediator that simplifies the connection while maintaining the necessary mechanical strength and adjustability.
2Manufacturing precision
If custom-made implants are used for pectus carinatum treatment, then treatment precision is improved, but manufacturing complexity increases
Solution Approach 1:
The custom implant system is segmented into a standardized chest bar platform and patient-specific securing straps. The chest bar can be manufactured using standardized procedures, while the straps are customized based on patient anatomy. This segmentation allows precision to be achieved without requiring complete custom manufacturing of all components.
Solution Approach 2:
Customization is applied locally to the securing straps rather than the entire implant system. The chest bar maintains standardized dimensions and manufacturing processes, while only the strap portions are tailored to individual patient requirements. This local customization approach preserves manufacturing simplicity while achieving necessary precision.
3Reliability
If securing straps with channeled head elements are used, then strap locking reliability is improved, but device complexity increases
Solution Approach 1:
Instead of using a complex locking mechanism that actively engages to prevent strap removal, the design inverts the approach by using a channeled head element that passively guides and secures the strap through its shape. The strap is locked in place by the geometry of the channel rather than by an active locking action, simplifying the mechanism while maintaining reliability.
Solution Approach 2:
The locking function is extracted from a complex mechanical locking mechanism and implemented through the simple geometric feature of the channeled head element. The channel shape itself provides the locking action, eliminating the need for separate locking components and reducing overall device complexity.
Data Source
AI summary
A pectus carinatum sternal pull-back device is provided that includes an implantable subcutaneous chest bar, where a size, a curve, a length and a width of the implantable later chest bar are customized according to predetermined sternum and rib cage dimensions of a pectus carinatum patient, where the customized implantable subcutaneous chest bar includes through holes at the ends of the customized implantable subcutaneous chest bar, and at least a pair of securing straps, where the securing strap includes a channeled head element at a first securing strap end, a semi-ribbed strap, and a curved solid insertion element at a second end, where the channeled head element includes a barb for receiving and locking the semi-ribbed strap, where the securing strap is configured for insertion through the through holes of the implantable subcutaneous chest bar.