Additively Manufactured Tibial Baseplate for Stable Bone Fixation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Cementless tibial components in knee prostheses suffer from structural degradation due to interfaces between solid and porous portions, leading to delamination, galvanic effects, and reduced mechanical strength, which compromises implant stability and bone fixation.

Innovation Solution

A tibial baseplate with seamlessly integrated porous and solid portions, manufactured via additive manufacturing, featuring optimized thickness and distribution of porous structures and stabilization elements to enhance structural solidity and bone ingrowth, while minimizing micromotion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a modular tibial component with separate solid and porous portions is used, then the polymeric liner can be removably coupled and the surgeon can choose from different heights, but the interface between solid and porous portions facilitates degradation phenomena such as delamination and galvanic effect

Engineering Contradiction:

Improveremovable coupling of polymeric liner and selection of different heightsVSAvoidstructural solidity and mechanical strength of the interface

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the solid and porous portions into a single integral baseplate structure manufactured by additive manufacturing, eliminating the harmful interface between separate portions while preserving the modular capability for liner attachment and height selection through integrated fixation elements

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a monolithic tibial component with baseplate completely made in porous material is used, then bone ingrowth is promoted, but the structural solidity and mechanical strength are reduced

Engineering Contradiction:

Improvebone ingrowth and osteointegrationVSAvoidstructural solidity and mechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies local quality by creating regions of different porosity within the baseplate: highly porous regions contact the bone to promote ingrowth, while less porous or solid regions provide structural strength and support the polymeric liner, with the transition between regions seamlessly integrated through additive manufacturing

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If additive manufacturing is used to manufacture the tibial baseplate, then seamless integration of porous and solid portions is achieved, but the manufacturing complexity increases

Engineering Contradiction:

Improveseamless integration and embedded porous portionsVSAvoidadditive manufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent utilizes parameter changes in the additive manufacturing process, specifically varying the porosity parameters during fabrication to create regions of different density and pore structure within the same baseplate, enabling seamless integration of functional zones without separate assembly steps

Inventive Principle:

Principle #35Parameter changes

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 integrated design improves structural integrity, reduces delamination and galvanic effects, and ensures stable bone fixation by optimizing load transfer and micromotion, enhancing the longevity and performance of the implant.

Implementation Method 1

a porous material to be placed in contact with the bone in order to allow bone ingrown

Methodology Applied

Scientific EffectOsteointegration:

Implementation Method 2

manufactured via additive manufacturing

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS20250352349A1Tibial baseplate for tibial component of a knee prosthesis, tibial component comprising the tibial baseplate and method for manufacturing the tibial baseplate

Publication Date: 2025.11.20 LIMACORPORATE SPA

AI summary

A implant removal tool for a tibial baseplate. The implant removal tool includes an adapter having conjugated adapter teeth, a first adapter part, and a second adapter part. The first adapter part supports a cutting guide of the implant removal tool that is integral with the first adapter part, and the second adapter part is slidely coupling with the first adapter part allowing a relative translation between the first and the second adapter part.