3D Printed Synthetic Skin Layer for Surgical Bio-Models

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Solution Overview

Problem

Traditional methods for training surgeons, such as using cadavers, face ethical, religious, and cost constraints, and fail to provide accurate simulations of specific patient anatomies and pathological conditions, limiting the effectiveness of surgical skill development and simulation.

Innovation Solution

A method for manufacturing three-dimensional bio-models using medical image data to create synthetic skin layers with varying thicknesses, comprising a surface layer and a backing layer, which are 3D printed to accurately mimic real skin properties and anatomy, allowing for realistic surgical simulations and practice.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-layer synthetic skin is used, then the manufacturing process is simple, but the skin cannot simultaneously achieve both strength to hold sutures and flexibility to mimic real skin

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidskin property accuracy

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The synthetic skin is divided into two distinct layers: a surface layer (0.2-2mm thick) that provides flexibility and mimics real skin properties, and a backing layer that provides structural support and strength. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between flexibility and strength while maintaining manufacturability through sequential 3D printing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite material construction with different materials for the surface layer and backing layer. The surface layer uses materials optimized for flexibility and skin-like properties, while the backing layer uses materials optimized for strength and structural support. This composite approach enables the synthetic skin to simultaneously achieve both flexibility and strength.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If the synthetic skin layer thickness varies to match patient anatomy, then anatomical accuracy is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveanatomical accuracyVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The synthetic skin incorporates locally varied thickness by adjusting the backing layer thickness in different regions while maintaining a relatively constant surface layer thickness. This allows the overall skin thickness to match patient-specific anatomy obtained from medical imaging, achieving anatomical accuracy without complicating the surface layer manufacturing process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Patient-specific anatomical measurements are obtained from medical imaging data before manufacturing. This preliminary action allows the synthetic skin design to be customized to match the patient's exact anatomy, with varying thickness distributed throughout the skin layer to accurately represent individual anatomical variations.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If cadavers are used for surgical training, then realistic surgical practice is achieved, but ethical and religious restrictions are imposed

Engineering Contradiction:

Improvesurgical training effectivenessVSAvoidethical acceptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent creates synthetic skin that copies and mimics the properties of real human skin, including flexibility, strength, and response to surgical instruments. This copying approach provides a realistic surgical training medium that eliminates ethical and religious restrictions associated with cadaver use, while maintaining surgical training effectiveness.

Inventive Principle:

Principle #26Copying

4Reliability

If cadavers are used for surgical training, then surgical skill development is enabled, but high costs for preservation and disposal are incurred

Engineering Contradiction:

Improvesurgical training effectivenessVSAvoidtraining cost

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The synthetic skin is designed as a cost-effective, disposable alternative to expensive cadavers. Each synthetic skin can be used for surgical training and then discarded without the high preservation and disposal costs associated with cadavers, making surgical training more accessible and cost-effective.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS11705020B2Method of manufacturing a bio-model comprising a synthetic skin layer and bio-model comprising a synthetic skin layer

Publication Date: 2023.07.18 UNIVERSITI MALAYA

AI summary

A method of manufacturing a three dimensional bio-model from medical image data is described. The method comprises: identifying a skin layer in the medical image data; determining a thickness of the skin layer; generating three dimensional model data from the medical image data, the three dimensional model data comprising an indication of a synthetic skin layer, the synthetic skin layer comprising a surface layer and a backing layer, wherein a combined thickness of the surface layer and the backing layer is determined from the thickness of the skin layer; and three dimensional printing the three dimensional model data to provide a three dimensional bio-model.