Mould for Temporary Prosthetic Knee Component
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for creating temporary prosthetic spacers in the operating room face challenges such as imprecision, defects, poor adaptation to the patient's knee shape, and long preparation times during knee surgery, particularly when dealing with infections requiring antibiotic therapy.
Innovation Solution
A mould system comprising interlocking half-moulds with coupling flanges and fixing elements allows for rapid and precise moulding of temporary prosthetic components, enabling efficient production of articulated spacers that can be adjusted to fit individual knee anatomy, using medical cement that can be impregnated with antibiotics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional moulding methods are used in the operating room, then the process is simple to perform, but the manufacturing precision and quality of the prosthetic components deteriorate due to imprecisions and defects
Solution Approach 1:
The mould is divided into two separate half-moulds (first half-mould and second half-mould) that can be coupled together. Each half-mould can be independently positioned and fixed to the patient's knee, allowing for precise adaptation to the individual anatomy while maintaining a relatively simple overall system structure.
Solution Approach 2:
The half-moulds are designed with specific local features including coupling flanges for precise alignment, fixing elements for secure attachment, and injection ducts positioned at optimal locations for cement distribution. These localized quality enhancements ensure high manufacturing precision without requiring complex overall system design.
2Productivity
If traditional moulding methods are used, then the equipment required is simple, but the productivity deteriorates due to relatively long times for preparing the spacer during operation
Solution Approach 1:
The two half-moulds are designed as pre-fabricated components with all necessary features (coupling flanges, fixing elements, injection ducts, vent ducts) already in place. This preliminary preparation allows the surgeon to quickly assemble and use the mould system without time-consuming modifications or adjustments during the operation.
Solution Approach 2:
The coupling flanges and fixing elements integrate multiple functions into single components: the coupling flanges simultaneously provide alignment, connection, and stabilization of the half-moulds, while the fixing elements combine attachment and securing functions. This merging reduces the number of separate steps and components needed, improving productivity.
3Adaptability or versatility
If traditional moulding methods are used, then the procedure is quick to perform, but the adaptability deteriorates due to poor possibility of adapting the prosthetic components to the shape of the patient's knee
Solution Approach 1:
By dividing the mould into two separate half-moulds, each can be independently adapted to the specific contours and geometry of the patient's knee. This segmentation allows for superior adaptation to individual patient anatomy compared to a single-piece mould, while the precise coupling mechanism ensures the final component maintains high manufacturing precision.
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
The mould system enables fast, precise, and efficient production of temporary prosthetic components, reducing surgical time and improving fit, while allowing for antibiotic delivery to infected areas, thus aiding in infection treatment and facilitating the transition to a permanent prosthesis.
Implementation Method 1
receive a dose of medical cement in the liquid state and allow the solidification to form a temporary prosthetic component
Implementation Method 2
The temporary spacers are also impregnated with antibiotics in such a way as to release them gradually into the infected area after their application
Data Source
AI summary
Described is a mould (1) for making a temporary prosthetic component for a knee in an operating room comprising: a first half-mould (10); a second half-mould (20) which can be coupled to the first half-mould (10) for forming a moulding chamber (C) for a temporary prosthetic component made of medical cement; and elements (30) for fixing the first half-mould (10) to the second half-mould (20).Each fixing element (30) has a rod (31) configured for connecting the first half-mould (10) to the second half-mould (20) and defining a weakness neck (32) configured to allow a facilitated breakage of the rod (31).