Patient-Specific Titanium Mesh Implant Mold System
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Solution Overview
Problem
The surgical repair of defects in the skull and facial bones is challenging due to the difficulty in accurately restoring missing anatomy, especially with large or complex defects, and limited access anatomical sites, using traditional manual forming and pressworking methods with titanium mesh.
Innovation Solution
A mold system comprising a forming tool and a mold with non-adjacent surface features is used to shape titanium mesh into a patient-specific implant, allowing for permanent deformation and correct curvature, aided by imaging and rapid prototyping techniques, enabling precise restoration of anatomical contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual forming and pressworking methods are used to shape titanium mesh, then the implant can be formed, but accurate restoration of missing anatomy is difficult and positioning is compromised
Solution Approach 1:
The patent uses a mold that replicates the exact anatomical contours of the defect-free skeletal region. The mold is created from imaging data (CT or MRI scans) to create a precise positive model, which then serves as a template for forming the implant. This copying approach ensures that the implant accurately restores the missing anatomy without requiring complex manual shaping skills.
Solution Approach 2:
The mold is prepared in advance based on pre-operative imaging data, allowing the exact anatomical contours to be established before surgery. The implant is pre-formed to match the patient's specific anatomy, eliminating the need for complex intraoperative shaping and ensuring accurate positioning.
2Adaptability or versatility
If titanium mesh is formed with complex contours or in limited access anatomical sites, then the implant can cover the defect, but stable molding and correct positioning become compromised
Solution Approach 1:
The mold includes specific surface features (protrusions, grooves, or engagement structures) at localized positions that correspond to the anatomical landmarks of the defect site. These local features provide stable engagement points for the titanium mesh during forming, ensuring reliable molding even for complex contours or hard-to-reach anatomical sites.
3Productivity
If traditional pressworking with cavity and punch is used, then the implant can be formed, but accurate restoration is compromised by problems with stable molded implant formation
Solution Approach 1:
Instead of using a generic cavity and punch system, the patent employs a custom mold that is a precise copy of the patient's specific anatomical defect-free region. This ensures that the forming process produces an implant with exact anatomical accuracy while maintaining forming efficiency through a straightforward press-in operation.
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
This method allows for accurate and permanent shaping of titanium mesh implants to correct skeletal defects, improving the precision and effectiveness of skull and facial bone reconstruction by ensuring correct curvature and positioning, even in complex or hard-to-reach areas.
Implementation Method 1
enabling the implant forming material to be stretched beyond its elastic and thus permanently deformed with the correct patient-specific curvature
Implementation Method 2
the surface features are configured to locally secure the implant forming material between the mold and the forming tool
Data Source
AI summary
Methods and apparatus are provided for forming a patient-specific surgical implant based on mold system. The apparatus comprises a forming tool and a mold that may be generated using imaging and processing techniques and rapid prototyping methods. The mold apparatus includes at least two non-adjacent surface features for securing an implant forming material (such as a titanium mesh) during the forming process, enabling the implant forming material to be stretched beyond its elastic and thus permanently deformed with the correct patient-specific curvature. The implant may include one or more anatomic surface features for guidance and registration when transferring the implant to a patient.