3D Printed Trial Implant Head with Reinforcing Core
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Solution Overview
Problem
Current trial implants for spinal surgery are costly and resource-intensive to produce, and do not easily accommodate individual anatomical variations, making them inefficient for precise fitting in intervertebral spaces.
Innovation Solution
A modular trial implant system featuring a 3D-printed head and shaft with a reinforcing core, where the head is customized for individual patient anatomy and the shaft can be made using 3D printing or conventional methods, allowing for rapid and cost-effective production, and the reinforcing core provides necessary rigidity and is designed to be biocompatible and non-invasive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If trial implants are manufactured using ablative manufacturing processes from solid material, then sufficient strength and rigidity are achieved, but production time and production costs increase significantly
Solution Approach 1:
The patent applies additive manufacturing (3D printing) instead of traditional ablative manufacturing processes. This fundamental change in the manufacturing parameter enables cost-effective and rapid production of trial implants while maintaining the necessary mechanical properties through material selection and design optimization
Solution Approach 2:
The patent employs composite materials, specifically carbon fiber reinforced polyether ether ketone (CFR-PEEK), which combines the high strength and rigidity of carbon fibers with the biocompatibility and processability of PEEK. This composite material approach allows additive manufacturing to produce implants with sufficient mechanical properties without the high costs and long production times of traditional methods
2Productivity
If trial implants are produced in standardized sizes, then manufacturing efficiency improves, but individual anatomical variations cannot be accommodated
Solution Approach 1:
The patent implements a digital planning process using pre-operative imaging (CT or MRI scans) to create patient-specific 3D models and plan the optimal implant dimensions before surgery. This preliminary action enables the head to be individually customized through additive manufacturing while the shaft can use standardized components, thus achieving both efficiency and adaptability
Solution Approach 2:
The patent divides the trial implant into two functional segments: a patient-specific head that requires customization for anatomical fit, and a standardized shaft that can be manufactured using conventional processes. This segmentation allows the head to be individually adapted while maintaining manufacturing efficiency through standardized components
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
Enables quick and cost-effective production of customized trial implants with sufficient rigidity and biocompatibility, allowing precise measurement of intervertebral spaces for optimal cage implantation without tissue damage, while being adaptable for single or multiple uses.
Implementation Method 1
the at least one head (12) is produced by means of 3D printing
Implementation Method 2
the at least one head (12) and the at least one shaft (18) are made of plastic
Data Source
AI summary
The present invention relates to a trial implant, in particular for spinal surgery, a total knee or hip endoprosthesis or a shoulder prosthesis, with at least one head, with at least one reinforcing core and with at least one stem, wherein the head is produced by means of 3D printing, and wherein the head and the stem are made of plastic.