Spinal Implant Solid Frame Porous Inner Layer Bone Integration
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Solution Overview
Problem
Existing spinal implants with porous structures face challenges in manufacturing complexity and limited porous material distribution, which affects bone growth and implant stability.
Innovation Solution
A spinal implant design featuring a solid frame with an inner porous layer, optimized for bone ingrowth, manufactured using additive manufacturing processes, and incorporating features like ribs and serrations for enhanced fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porous material is used extensively in spinal implants to encourage bone growth, then bone integration is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The implant is divided into distinct porous and solid regions. The porous material is segmented to specific zones where bone growth is most needed, while other regions maintain solid structure for strength. This segmentation allows bone integration benefits without requiring the entire implant to be porous, thus reducing manufacturing complexity.
Solution Approach 2:
Different regions of the implant have different material properties - porous in some areas and solid in others. The porous material is placed locally at interfaces where bone contact is critical, while solid material provides structural support. This local differentiation optimizes both bone integration and manufacturing feasibility.
2Ease of manufacture
If porous material is used in limited areas (thin layers) to maintain strength, then manufacturing is simplified, but bone growth surface area is reduced
Solution Approach 1:
The porous material is extended into the third dimension by creating internal porous cavities and channels within the implant structure. This allows significantly increased bone growth surface area without proportionally increasing external dimensions or manufacturing complexity, as the porosity is utilized internally throughout the implant volume.
Solution Approach 2:
Porous structures are nested within the solid implant framework. The porous material is positioned inside cavities and channels of the solid structure, maximizing bone growth surface area within the existing external dimensions. This nested arrangement increases functional surface area without requiring larger external dimensions or proportionally more material.
3Reliability
If extensive porous material is used to maximize bone growth, then bone integration is improved, but implant strength may be compromised
Solution Approach 1:
The implant features local quality differentiation where porous material is placed specifically at bone-contact interfaces and load-transfer zones, while solid material provides the primary load-bearing framework. This ensures that porosity is concentrated where it benefits bone integration most, while solid regions maintain structural strength.
Solution Approach 2:
The implant functions as a composite structure combining porous and solid materials in a unified design. The porous and solid regions work together synergistically - the porous areas facilitate bone ingrowth while the solid areas provide mechanical strength. This composite approach allows both bone integration and strength requirements to be met simultaneously.
Data Source
AI summary
Disclosed herein is a spinal implant with a solid frame and a porous inner layer. The implant may have a cavity defined by the porous inner layer. The solid frame may have one or more ribs extending from a medial wall to a lateral wall. The thickness of the porous layer may vary relative the thickness of the solid frame at various locations. An inserter to place a spinal implant and a method to perform same are also disclosed.