Spinal Connecting Rod Bending for Intraoperative Alignment
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Solution Overview
Problem
Existing methods for manufacturing spinal rods for attachment elements fail to adequately account for intraoperative hazards and sterility constraints, leading to potential loss of correction objectives and suboptimal rod positioning.
Innovation Solution
A method involving preoperative planning and intraoperative data acquisition to create virtual rods, followed by actual rod manufacturing using a sterilizable bending device, ensuring sterility and precise alignment with attachment elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If preoperative planning is used to manufacture a connecting rod, then the correction objective is established, but intraoperative hazards such as actual position of attachment elements cannot be taken into account
Solution Approach 1:
The system performs preliminary scanning and virtual rod creation before final rod manufacturing, allowing the actual attachment element positions to be captured and incorporated into the manufacturing process. The scanner acquires spatial coordinates of attachment elements, and a virtual rod is generated based on these actual positions rather than preoperative estimates.
Solution Approach 2:
The system creates a virtual copy of the rod based on actual scanned data from the patient's anatomy and attachment elements. This virtual rod serves as a digital model that can be manipulated and optimized before manufacturing the physical rod, ensuring it matches the actual intraoperative conditions.
2Measurement precision
If a substitution rod is used for acquisition, then the position of attachment elements can be determined, but aseptic conditions cannot be guaranteed during acquisition and manufacturing
Solution Approach 1:
The system separates the scanning/acquisition function from the final rod manufacturing process. A scanner (which can be sterilized) is used to acquire attachment element positions, and this data is transferred to create a virtual rod model. The actual rod is then manufactured based on this digital model without requiring the substitution rod to remain in place, reducing sterility risks.
Solution Approach 2:
The virtual rod model serves as an intermediary between the physical attachment elements and the final rod manufacturing. The scanner captures data from the actual attachment elements, creates a digital representation, and this virtual model guides the manufacturing of the final rod, eliminating the need for prolonged presence of substitution rods in the sterile field.
3Adaptability or versatility
If intraoperative acquisition of attachment element positions is performed, then adaptability to actual conditions is improved, but the correction objective may be lost
Solution Approach 1:
The system incorporates feedback by comparing the virtual rod (based on actual attachment element positions) with the preoperative correction plan. The virtual rod can be adjusted to ensure it achieves the desired correction objectives while accommodating the actual positions of attachment elements. This iterative adjustment process ensures both adaptability and precision.
Solution Approach 2:
The system allows dynamic adjustment of the virtual rod model based on actual intraoperative conditions. The virtual rod can be modified to optimize both the correction objective and the fit with actual attachment elements, creating a flexible planning process that adapts to real-world variations while maintaining surgical goals.
Data Source
AI summary
Disclosed is a method for manufacturing a connecting rod between attachment elements secured to the spine of a patient, the method including: —planning the manufacturing of a first virtual rod based on the patient's anatomical data, —positioning and securing the attachment elements on the patient's body, —intraoperatively acquiring the position of the attachment elements for the purpose of creating a second virtual rod, —analyzing the first and second virtual rods for the purpose of creating a third virtual rod, —intraoperatively manufacturing a real rod from the third virtual rod by a bending device. Also disclosed are the device and the connecting rod allowing the method to be carried out.