Patient-Specific Surgical Instrument Metallic Insert

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Solution Overview

Problem

Current orthopaedic surgical instruments are generic and lack patient-specific customization, leading to inaccuracies in joint replacement procedures as surgeons must estimate the placement of instruments on varying bone structures.

Innovation Solution

Development of a customized orthopaedic surgical instrument with a metallic insert and polymeric body, featuring a snap feature and keyway configuration, which includes a patient-specific contour to accurately match the bone's shape, reducing the need for manual alignment and enhancing precision during surgical procedures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If generic orthopaedic surgical instruments are used, then the instrument can be used on multiple patients, but the placement accuracy on individual bone structures deteriorates

Engineering Contradiction:

Improveinstrument reusabilityVSAvoidplacement accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The surgical instrument is divided into two distinct parts: a generic polymeric body that can be reused, and a patient-specific metallic insert that ensures accurate placement. The insert is custom-manufactured to match the individual patient's bone anatomy while the polymeric body remains a standardized component that can be used across multiple procedures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metallic insert incorporates patient-specific anatomical contours and features that are unique to each patient's bone structure. This local customization is applied only to the insert portion that contacts the bone, while the rest of the instrument body remains generic and unchanged.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If customized patient-specific instruments are manufactured, then placement accuracy improves, but the device complexity and manufacturing process worsen

Engineering Contradiction:

Improveplacement accuracyVSAvoidinstrument structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patient-specific metallic insert is nested within the generic polymeric body. The insert fits into a recess or cavity in the polymeric body, combining the benefits of customization with a standardized outer structure. This nesting approach reduces overall complexity compared to manufacturing entirely custom instruments for each patient.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The instrument combines two different materials with distinct properties: a polymeric body for the generic reusable portion and a metallic insert for the patient-specific customized portion. Each material is selected for its optimal properties, and their combination allows the instrument to achieve both accuracy and reusability.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If a metallic insert is secured to a polymeric body via snap feature, then assembly ease improves, but the risk of exceeding polymeric material yield strength worsens

Engineering Contradiction:

Improveassembly easeVSAvoidpolymeric material strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The snap feature incorporates a deflectable element that dynamically adjusts during assembly. The deflection allows the snap feature to temporarily exceed the normal stress limits of the polymeric material without causing permanent damage, then returns to a stable position that secures the metallic insert firmly in place.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The snap feature design anticipates the potential for exceeding yield strength during assembly by incorporating a deflection mechanism that absorbs the excess force. This cushioning effect prevents permanent damage to the polymeric body while still achieving secure attachment of the metallic insert.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 customized instrument ensures precise placement and alignment of cutting guides and surgical tools, reducing guesswork and improving the accuracy of surgical interventions by matching the instrument's contour to the patient's bone, thus facilitating better implantation of orthopaedic prostheses.

Implementation Method 1

The metallic insert is secured to a polymeric body of the orthopaedic surgical instrument via a snap feature that deflects during assembly without exceeding the yield strength of the polymeric material

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10251654B2Customized patient-specific surgical instrument with metallic insert

Publication Date: 2019.04.09 DEPUY SYNTHES PROD INC

AI summary

A surgical cutting guide including a customized, patient-specific contour is disclosed. The surgical cutting guide includes a metallic insert to guide a cutting tool in cutting a patient's bone.