Thin Channel Implant for Orbital Reconstruction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current channel implants used in craniofacial surgery, particularly for orbital reconstruction, are excessively thick due to manufacturing limitations, leading to undesirable bulges and potential overlift of the eye following implantation.
Innovation Solution
The development of channel implants with a thickness of less than 1.75 mm, manufactured by laminating two porous sheets with a removable mold core, resulting in a uniform thickness and eliminating the bulge, and optionally featuring a membrane layer or pre-installed malleable metal and radio opaque strips for enhanced integration and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If traditional manufacturing methods are used to create channel implants, then the implant can be manufactured with sufficient structural integrity, but the implant thickness becomes excessively thick (greater than 1.75 mm) causing undesirable bulges and potential overlift of the eye
Solution Approach 1:
The implant is divided into multiple layers (first porous layer, second porous layer, and intermediate layer) that are manufactured separately and then assembled. This segmentation allows each layer to be optimized independently, enabling the creation of thin-walled structures with sufficient structural integrity while maintaining porosity for tissue integration.
Solution Approach 2:
A removable core element is nested within the implant structure during manufacturing. The core defines the internal channel geometry, and after the porous layers are formed around it, the core is removed to create the fixation channel. This nesting approach enables precise channel formation without requiring thick walls.
2Length of stationary object
If the implant thickness is reduced to less than 1.75 mm, then the risk of overlift and bulging is reduced, but the structural support and fixation strength may be compromised
Solution Approach 1:
The implant uses composite construction with porous layers (for tissue integration) combined with a dense intermediate layer or membrane (for structural support). This composite approach allows thin overall thickness while maintaining sufficient fixation strength through the intermediate structural layer.
Solution Approach 2:
Different regions of the implant have different properties: the porous layers provide tissue integration capability, the intermediate layer provides structural support and fixation strength, and the channel regions provide fixation plate access. This local differentiation of material properties allows thin overall thickness while maintaining strength where needed.
3Length of stationary object
If the implant walls are made thin to reduce overall thickness, then the implant profile is improved, but the porosity and tissue integration capability may be reduced
Solution Approach 1:
The implant structure is segmented into distinct porous layers that maintain high porosity for tissue integration, separated by thin intermediate structural layers. This segmentation allows the porous regions to remain thick enough for tissue ingrowth while the overall implant thickness is reduced by the thin intermediate layers.
Solution Approach 2:
The implant uses porous materials in the first and second layers to ensure tissue integration capability is maintained. The porosity is preserved in these layers despite the reduced overall thickness, as the porous structure is maintained through controlled manufacturing processes that prevent wall thickening.
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 thinner channel implants provide improved structural support with reduced risk of overlift, maintaining porosity for tissue integration while allowing for precise shaping and fixation, enhancing surgical outcomes in delicate craniofacial applications.
Implementation Method 1
thermally processing the assembled structure
Data Source
AI summary
Embodiments relate generally to channel implants used for surgical reconstruction and/or repair. Certain embodiments of the channel implants are designed for craniofacial surgery, reconstruction, and/or augmentation. More specifically, some embodiments find particular use in orbital reconstructive surgery, such as repair of the orbital floor or supraorbital ridge (brow ridge). Embodiments also relate to methods for using and for manufacturing the channel implants disclosed.