Star-Shaped Porous Titanium Implant Structure
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Solution Overview
Problem
Conventional methods for producing porous titanium surgical implants struggle to replicate the three-dimensional porosity of bone tissue, leading to inadequate integration and mechanical properties, as existing processes fail to accurately control pore size and shape, resulting in implants with poor colonization by bone cells and low mechanical strength.
Innovation Solution
A porous structure with a controlled pattern, featuring three wings arranged in a star shape with 120° angles and beveled tips, allowing for adjustable dimensions to optimize porosity and mechanical properties, is created using layer-by-layer fusion of titanium powder by electron beam or laser beam melting, enabling better manufacturing precision and bone-like integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding processes are used to produce porous implants, then the implant shape can be obtained, but the pore size and porosity rate cannot be controlled
Solution Approach 1:
The invention creates a master model with the desired porous structure before producing the final implant. This master model serves as a template that pre-defines the pore architecture, allowing precise control of pore size and distribution in the final product without requiring complex real-time control during implant manufacturing
Solution Approach 2:
The invention introduces an intermediate master model as a mediator between the manufacturing process and the final implant. This master model, created with controlled porosity through layer-by-layer assembly, acts as a template that transfers the desired pore structure to the final implant, decoupling the complexity of pore control from the implant manufacturing process
2Reliability
If porosity is increased to improve bone integration, then bone cell colonization improves, but mechanical strength decreases
Solution Approach 1:
The invention applies different pore sizes and porosity levels to different regions of the implant based on local requirements. The master model allows customization of pore architecture in specific zones, enabling high porosity in regions requiring bone integration while maintaining lower porosity in load-bearing regions to preserve mechanical strength
Solution Approach 2:
The invention divides the implant into multiple layers with different pore characteristics during master model creation. Each layer can have customized porosity and pore size, allowing optimization of bone integration in certain layers while maintaining mechanical strength in other layers, thus resolving the contradiction between porosity and strength
3Strength
If the rhombic dodecahedron pattern is used, then theoretical mechanical properties are optimized, but manufacturing precision and structural regularity deteriorate
Solution Approach 1:
The invention uses a simplified cubic pattern as a copy or approximation of the ideal rhombic dodecahedron structure. This cubic pattern maintains the essential mechanical properties and space-filling characteristics while being much easier to manufacture with regular geometry, thus achieving good mechanical properties with high manufacturing precision
Solution Approach 2:
The invention modifies the geometric parameters of the pattern from the ideal rhombic dodecahedron to a simpler cubic form. This parameter change simplifies the geometry while preserving the key functional characteristics, allowing precise manufacturing while maintaining adequate mechanical properties
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 star-shaped pattern enhances bone integration and mechanical properties, providing a more stable and porous structure that closely mimics bone tissue, with improved colonization and mechanical characteristics compared to previous designs, such as the rhombic dodecahedron pattern.
Implementation Method 1
a first layer of titanium powder which is deposited in the bottom of a tank is fused locally at the desired locations by an electron beam or a laser beam
Implementation Method 2
a first layer of titanium powder which is deposited in the bottom of a tank is fused locally at the desired locations by an electron beam or a laser beam
Implementation Method 3
a first layer of titanium powder which is deposited in the bottom of a tank is fused locally at the desired locations
Data Source
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AI summary
The present invention relates to a porous structure having a controlled pattern (1), which is repeated in space in three dimensions, said porous structure enabling the production of surgical implants for filling in bone defects. According to the invention, said structure is characterized in that said pattern (1) consists of three flanges (2) arranged in a star shape, each angle (A) formed between two flanges being substantially equal to 120°, each flange having a generally rectangular shape and being recessed (3) at the center thereof. Each of the three flanges (2) of said pattern is advantageously beveled at the free end or tip (4) thereof, and the width of the base (5) of each bevel is slightly greater than the thickness of the flange (2) of which it forms an extension.