Oxide-Layer Zirconium-Niobium Tibial Plateau Prosthesis for Bone Ingrowth
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Solution Overview
Problem
Existing knee prostheses face issues with bone cement fixation leading to safety risks and poor bone ingrowth, and traditional manufacturing methods struggle to create complex structures with high bonding strength and mechanical properties.
Innovation Solution
A tibial plateau prosthesis with trabeculae containing a zirconium-niobium alloy oxidation layer is fabricated using 3D printing and subsequent heat treatment, followed by precise machining and oxidation layer formation to enhance bonding strength and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cemented prosthesis is used to mechanically fix the joint prosthesis and bone tissue, then fixation strength is improved, but safety risks increase due to heat release, cement particles entering bloodstream, and high pressure in medullary cavity
Solution Approach 1:
The invention extracts and eliminates the bone cement component from the fixation system, transitioning to a cementless prosthesis that achieves fixation through direct bone ingrowth into porous surface structures, thereby removing the source of harmful effects while maintaining fixation functionality
Solution Approach 2:
The invention applies porous surface structures to the prosthesis surface, enabling bone ingrowth and biological fixation without requiring bone cement, thus achieving both fixation strength and safety by eliminating cement-related harmful effects
2Reliability
If porous surface structures are created by sandblasting, coating, sintering or other surface treatments, then bone ingrowth is promoted, but bonding strength with matrix decreases and service life reduces
Solution Approach 1:
The invention applies different surface treatments to different regions of the prosthesis: porous surface structures are created on the bone-contacting surfaces to promote bone ingrowth, while the matrix maintains high density and strength, achieving both bone ingrowth promotion and high bonding strength through localized property differentiation
Solution Approach 2:
The invention creates a composite structure combining porous surface layers with high-strength matrix material, where the porous layer promotes bone ingrowth and the dense matrix provides mechanical strength and bonding, achieving synergistic performance
3Stress or pressure
If trabecular layer is designed as the only transition layer from axial view, then stress distribution is improved, but stress shielding occurs due to high elastic modulus of prosthesis metal versus low elastic modulus of bone tissue
Solution Approach 1:
The invention applies different elastic modulus materials to different regions: the trabecular layer uses a material with intermediate elastic modulus to distribute stress, while the matrix uses high-strength material, creating localized property gradients that reduce stress shielding while maintaining stress distribution
4Ease of manufacture
If traditional manufacturing methods are used, then production process is simple, but complex structures with high bonding strength and mechanical properties cannot be achieved
Solution Approach 1:
The invention utilizes controllable parameters of the 3D printing process (layer thickness, infill density, support structure, temperature, pressure) to precisely fabricate complex internal trabecular structures and porous surface features, achieving high manufacturing precision for complex geometries while maintaining process feasibility
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 prosthesis achieves improved bone ingrowth, enhanced mechanical properties, and reduced wear rates, with a stable oxidation layer that prevents detachment and supports osseointegration.
Implementation Method 1
Zirconium-niobium alloy can react with N, C, O or other elements to form a hard oxidation layer on the surface
Implementation Method 2
3D printing technology, as an additive manufacturing technology, breaks through the manufacturing process-oriented product design concepts
Implementation Method 3
A tibial plateau prosthesis with trabeculae containing a zirconium-niobium alloy oxidation layer is fabricated using 3D printing and subsequent heat treatment
Data Source
AI summary
The present disclosure discloses a tibial plateau prosthesis with trabeculae containing zirconium-niobium alloy on oxidation layer and a preparation method thereof. The preparation method uses zirconium niobium alloy powder as raw material, conducting a 3D printing for one-piece molding to obtain an intermediate product of the tibial plateau, performing hot isostatic pressing and cryogenic oxidation to obtain the tibial plateau prosthesis comprising a proximal trabecular layer and a distal trabecular layer; the pore size and porosity of the proximal trabecular layer are evenly arranged, and the distal trabecular layer are partitioned; the topological structure of the trabeculae of the tibial plateau prosthesis is gradiently distributed from three dimensions; the micro-strain in the 64%-72% region of the finite element model of the tibial plateau bone tissue is between the minimum effective strain threshold and the supraphysiological strain threshold, which increases the mechanical adaptation of the prosthesis.