3D-Printed Spinal Fusion Implant With Trabecular Osteoinductive Surface
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Solution Overview
Problem
Current spinal fusion devices lack effective features to stimulate new bone growth between adjacent vertebrae, relying on bone grafts and osteoinductive agents for fusion, which can be inefficient and require additional surgical procedures.
Innovation Solution
A spinal implant fusion device fabricated using 3D printing with a structure mimicking trabecular bone, featuring interconnected struts and nano channels etched through laser processing to enhance osteoinductivity and facilitate bone growth, combining additive manufacturing with subtractive laser technology to create a biologically active surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional spinal fusion devices are used, then mechanical support is provided, but bone growth stimulation is insufficient
Solution Approach 1:
The implant incorporates a porous structure with interconnected struts and channels that mimic trabecular bone architecture. This porous framework provides mechanical support while simultaneously facilitating bone ingrowth and osteoinduction, resolving the contradiction between strength and bone growth stimulation.
Solution Approach 2:
The device combines different materials and structures - a solid outer shell for mechanical strength and a porous inner structure for bone growth. This composite approach allows the implant to simultaneously provide structural support and promote osteogenesis.
2Reliability
If bone graft material is used, then bone growth is stimulated, but additional surgical procedures are required
Solution Approach 1:
The invention merges the structural support function and the bone growth stimulation function into a single integrated implant device. The porous structure itself serves as both the mechanical framework and the osteoinductive element, eliminating the need for separate bone grafting procedures.
Solution Approach 2:
The implant's porous structure automatically promotes bone growth through its inherent architecture that mimics natural trabecular bone. The device self-services the bone regeneration function without requiring additional surgical intervention to introduce separate bone graft materials.
3Strength
If solid structure is used, then mechanical strength is provided, but bone integration is reduced
Solution Approach 1:
The implant uses a porous structure with controlled porosity that maintains mechanical strength while enabling bone integration. The interconnected struts provide structural support, while the void spaces allow bone cells to infiltrate and grow, resolving the trade-off between strength and bone integration.
Solution Approach 2:
The design transitions from a solid three-dimensional structure to a porous three-dimensional structure with hierarchical porosity. This dimensional modification at the micro-scale enables bone integration while maintaining macro-scale mechanical strength through the strut framework.
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 device effectively promotes bone attachment and growth, enhancing the fusion process by replicating the porosity and structure of trabecular bone, thereby improving the load-bearing capacity and osteoinductive properties of spinal implants.
Implementation Method 1
fabricating an implant body structure using 3D printing to create the implant body structure; additively building the body structure
Implementation Method 2
subsequent subtractive laser etching which results in nanometer-level structure on at least a portion of a surface or surfaces of the implant body structure
Data Source
AI summary
The present invention relates to an implant fusion device and a method of manufacturing an implant fusion device. More particularly an orthopedic or spinal implant configured to be implanted between adjacent vertebrae or within a gap in a bone or between bones, the device having a manufactured body structure simulating the physical characteristics of trabecular bone, but with improved osteoinductive features on the exterior surface wherein the device is fabricated using 3D printing. Alternatively, the implant may be made through 3D printing in a manner that results in a relatively or completely solid structure, but with a surface that mimics trabecular bone structure.