Polymer Implant Cutting and Bending Tool for Craniofacial Defects
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Solution Overview
Problem
Existing orthopedic implants are difficult to manufacture in a one-size-fits-all solution due to varying craniofacial defects and skull shapes, necessitating custom cutting and shaping during surgical procedures.
Innovation Solution
A tool with a bending and cutting portion, featuring prongs and a blade, designed to reshape polymeric implants by bending and cutting them to match specific defect sizes and shapes, allowing for precise adaptation to individual craniofacial defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If orthopedic implants are manufactured in standard sizes and shapes, then manufacturing cost and complexity are reduced, but the implants cannot conform to varying craniofacial defect sizes and shapes
Solution Approach 1:
The patent combines multiple functions (cutting, bending, shaping) into a single integrated orthopedic implant tool. The tool features a handle with a cutting portion including a blade and a bending portion with prongs, allowing surgeons to perform both cutting and bending operations on polymeric implants during the same surgical procedure, thereby reducing the need for multiple separate instruments and simplifying the overall surgical process
2Ease of operation
If multiple separate tools are used for cutting and bending implants, then each tool can be optimized for its specific function, but the surgical procedure becomes more complex and time-consuming
Solution Approach 1:
The patent merges cutting and bending capabilities into one tool, allowing surgeons to perform both operations sequentially on the implant during a single surgical procedure. The cutting portion with the blade can trim the implant to the desired size, and then the bending portion with prongs can reshape it to match the defect geometry, all without changing instruments
Solution Approach 2:
The tool is designed to perform preliminary shaping operations (cutting and bending) directly in the operating room before implant insertion. This allows the implant to be customized to the specific defect geometry right before implantation, ensuring optimal fit without requiring extensive intraoperative adjustments after the implant is already in place
3Manufacturing precision
If a monolithic implant design is used, then manufacturing is simplified, but the implant cannot be customized to match specific defect geometries
Solution Approach 1:
The patent employs a polymeric implant material that can be mechanically modified through cutting and bending operations. The implant starts as a monolithic piece with standard dimensions, but its physical parameters (size, shape, curvature) can be changed during surgery by applying mechanical forces through the tool's blade and prongs, allowing precise customization to match the specific defect geometry while maintaining manufacturing simplicity
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
Enables surgeons to efficiently cut and shape orthopedic implants to conform to the unique dimensions and curvatures of craniofacial defects, improving the fit and effectiveness of implants during surgical reconstruction.
Implementation Method 1
a force applied to the bending portion causes the first and second bending prongs to bend the received portion of the polymeric implant
Implementation Method 2
a force applied to the bending portion causes the first and second bending prongs to bend the received portion of the polymeric implant to a second shape different than the first shape
Data Source
AI summary
A first tool is configured to cut a polymer implant, and includes a handle, a cutting portion, and a bending portion. A second tool is configured to cut a polymer implant, and includes a handle, a first cutting portion, and a second cutting portion. The cutting portions contain a cutter that is preferably a blade. In the second tool, the blades are preferably angled with respect to each other between about 45°. The tools can be used to reshape an implant that is to be used to replace a portion of a skull.