Standardized Mold for Custom Tibial Prostheses

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Solution Overview

Problem

Current methods for manufacturing proximal tibial prostheses are limited in size, leading to inadequate fit and increased labor and cost due to the need for numerous molds, resulting in discomfort and complications for patients undergoing artificial knee joint surgery.

Innovation Solution

A method involving the formation of a tibial element data table to categorize and group data, manufacturing standard molds based on these groups, and using these molds to create patient-customized prostheses by selecting the closest matching mold size to patient data, thereby reducing the number of molds required and minimizing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a large number of molds are prepared to manufacture proximal tibial prostheses of various sizes, then the adaptability to different patient sizes is improved, but the device complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improveadaptability to different patient sizesVSAvoidnumber of molds required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single standardized mold that can produce proximal tibial prostheses of multiple sizes. The mold is configured with a standardized structure that allows it to function as a universal template, enabling the fabrication of different sized prostheses through controlled material deposition processes rather than requiring separate specialized molds for each size variant.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent utilizes parameter changes by modifying the deposition parameters (such as material layer thickness, deposition rate, and scanning patterns) during the additive manufacturing process to produce prostheses of different sizes from the same mold. This allows the standardized mold to adapt to different size requirements by changing process parameters rather than requiring different physical molds.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If a large number of molds are prepared to manufacture proximal tibial prostheses of various sizes, then the adaptability to different patient sizes is improved, but the manufacturing cost increases due to excessive labor and management requirements

Engineering Contradiction:

Improveadaptability to different patient sizesVSAvoidmanufacturing cost and labor

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The standardized mold serves multiple functions across different prosthesis size productions, eliminating the need to manufacture, store, and manage multiple specialized molds. This universal mold reduces material costs, labor for mold fabrication, and overhead costs associated with inventory management of numerous mold variants.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent employs copying by using the same standardized mold design for producing all prosthesis sizes, where the fundamental mold structure is copied and reused rather than creating unique molds for each size. This copying approach significantly reduces the overall manufacturing cost and simplifies the production system.

Inventive Principle:

Principle #26Copying

3Ease of manufacture

If limited size options are used for proximal tibial prostheses, then the manufacturing process is simplified, but the fit quality and patient comfort deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfit quality to patient anatomy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical molding methods with additive manufacturing (3D printing) technology. This substitution enables precise control over the prosthesis geometry and material properties during the building process, allowing for customized fits based on patient-specific anatomical data while maintaining manufacturing simplicity through digital modeling and automated deposition processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes parameter changes in the additive manufacturing process to achieve precise fit quality. By adjusting deposition parameters, layer thickness, and material properties during the printing process, the system can produce highly accurate, patient-specific prostheses from a standardized mold, thereby maintaining manufacturing simplicity while achieving superior fit quality.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10172713B2Method of manufacturing patient-customized tibial element

Publication Date: 2019.01.08 CORENTEC

AI summary

A method of manufacturing a patient-customized tibial element for use in artificial knee joint surgery. A tibial element data table regarding sizes of proximal tibial prostheses is formed. Standard molds able to cover the tibial element data table are manufactured. A standard mold is selected from the standard molds in order to manufacture a patient-customized proximal tibial prosthesis. A proximal tibial prosthesis fitting a patient is formed using the selected standard mold.