Point-of-Need Custom Part Manufacturing for Biomechanical Fit
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Solution Overview
Problem
Current manufacturing processes struggle to produce custom parts that accurately match the unique mechanical properties and geometries of aged or damaged components, especially in biological systems, leading to inefficiencies and potential failure due to mismatched stiffness and stress concentrations.
Innovation Solution
A method and system for point-of-care manufacturing that involves scanning a location to generate a custom topology map, matching it to a template, and using localized manufacturing devices to produce custom parts with spatially resolved biomechanical requirements, incorporating material properties and geometric performance to restore function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If generic replacement parts are used, then manufacturing complexity is reduced, but functional performance deteriorates due to mismatched mechanical properties and geometries
Solution Approach 1:
The patent applies local quality by creating replacement parts with spatially varying material properties and geometries that match the specific wear and damage patterns of the original component. Instead of uniform replacement parts, the system generates customized parts with locally optimized characteristics based on scanned topology and wear analysis, thereby improving functional performance without excessive manufacturing complexity.
Solution Approach 2:
The system changes material parameters and geometric parameters of replacement parts based on scanned data of the original component. By adjusting these parameters to match the specific condition and wear patterns of the original part, the system achieves better functional performance while using standardized manufacturing processes.
2Reliability
If custom parts are manufactured to match unique geometries, then functional performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses copying by scanning the original component to create a digital replica of its geometry and wear patterns. This digital copy serves as the basis for generating manufacturing instructions, allowing custom parts to be produced from standardized processes without requiring complex manual design and manufacturing procedures.
Solution Approach 2:
The system replaces manual manufacturing processes with automated manufacturing guided by digital models. By substituting mechanical design and fabrication with computer-aided manufacturing based on scanned data, the system achieves custom parts with improved functional performance while reducing actual manufacturing complexity.
3Manufacturing precision
If digital workflows are implemented for custom manufacturing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system applies self-service by enabling the manufacturing process to automatically generate customized parts from scanned data without extensive manual intervention. The digital workflow autonomously processes the scanning data, generates manufacturing instructions, and guides the manufacturing device, thereby achieving high manufacturing precision while managing system complexity through automation.
4Loss of time
If on-site manufacturing is performed, then loss of time is reduced, but device complexity increases
Solution Approach 1:
The system applies preliminary action by performing all necessary design and manufacturing operations on-site rather than relying on external suppliers. The portable manufacturing device and digital workflow enable complete custom part production at the location of need, eliminating lead time associated with shipping and external manufacturing, while the modular nature of the system keeps complexity manageable.
Data Source
AI summary
Systems and methods are disclosed to manufacture a custom repair or replacement part at the location in which the repair/replacement will be performed. Scans are performed to determine a wear pattern and topology of the location where the replacement part is to be placed and manufacturing instructions are generated to manufacture the repair part using localized manufacturing techniques according to customized parameters to meet functional requirements of the repair/replacement.