UV-Curing Resin Prosthesis Shaft Kit
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Solution Overview
Problem
Existing methods for creating prosthesis shafts for limb stumps, particularly lower leg stumps, are labor-intensive and require skilled craftsmanship, often involving multiple steps and materials like plaster.
Innovation Solution
A set comprising a medical apparatus with a pressure vessel and a membrane, used in conjunction with a deformable and curable material, allows for the direct creation of a prosthesis shaft by taking an impression of the limb stump and curing the material using an energy source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods using plaster and multiple materials are used to create prosthesis shafts, then the prosthesis can be created with good fit, but the process becomes labor-intensive and requires skilled craftsmanship
Solution Approach 1:
The invention changes the material state from deformable to cured through UV irradiation, transforming the manufacturing process from manual shaping to automated curing. The resin material is applied in a deformable state to capture stump geometry, then cured to achieve precise fit without requiring skilled manual craftsmanship.
Solution Approach 2:
The invention replaces manual mechanical shaping operations with UV light curing. Instead of skilled craftsmen manually molding and shaping plaster, the system uses UV irradiation to cure the resin material, substituting mechanical craftsmanship with optical energy-based processing.
2Manufacturing precision
If traditional multi-step methods are used, then the prosthesis can be created with adequate quality, but the production time increases
Solution Approach 1:
The invention merges the impression-taking and prosthesis-creation steps into a single integrated process. The resin material simultaneously captures the stump geometry and forms the final prosthesis shaft structure, eliminating separate steps for creating molds, patterns, and final products that characterize traditional multi-step methods.
Solution Approach 2:
The invention utilizes the phase transition of the resin material from deformable to cured state through UV irradiation. This phase change enables the material to first conform to the stump geometry in its deformable state, then lock in that shape and gain structural integrity upon curing, achieving both accuracy and efficiency in a single process.
3Manufacturing precision
If traditional methods with multiple materials are used, then the prosthesis shaft can be created, but material waste increases
Solution Approach 1:
The invention extracts and eliminates unnecessary intermediate materials from the traditional multi-material process. Instead of using plaster, molds, patterns, and other auxiliary materials, the system directly applies the resin material to the stump and cures it, taking out the extraneous material steps and reducing waste.
Solution Approach 2:
The invention employs a disposable single-use resin material that is applied directly to the stump, cured, and then removed as the finished prosthesis. This eliminates the need for reusable molds, patterns, and other equipment that require maintenance and cleaning, simplifying the process and reducing material waste.
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 enables the efficient and reproducible creation of well-fitting prosthesis shafts with reduced manual labor and costs, allowing for immediate use of the cured shaft as a prosthesis, thereby enhancing patient care and reducing production time and waste.
Implementation Method 1
a material which is deformable and curable by an energy source
Data Source
AI summary
A set for taking an impression of a limb stump or in generating a prosthesis shaft or a part thereof, comprises or consists of a medical apparatus, at least one energy source and a deformable material which may be cured by an energy source. The medical apparatus comprises at least one pressure vessel with a fluid chamber or a pressure chamber for receiving or storing a fluid, wherein the pressure vessel comprises a wall made of a first material and a fluid-tight membrane made of at least a second material, and an insertion opening for inserting the limb stump into the interior of the pressure vessel. The membrane is arranged to form or delimit the fluid chamber or the pressure chamber. The energy source is used to cure or partially harden the deformable material in order to achieve an impression of the limb stump or to produce a prosthesis shaft.