Variable Strut Lattice Surgical Implant for Weight and Strength Balance
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Solution Overview
Problem
Conventional surgical implant devices, such as spinal and orthopedic implants, face challenges in achieving adequate elasticity, bony ingrowth, and structural integrity while being difficult to manufacture, especially when incorporating internal voids like lattice volumes.
Innovation Solution
A surgical implant device with both solid surfaces and an internal lattice volume, featuring more numerous smaller pores and fine struts adjacent to solid surfaces, and fewer larger pores and thicker struts remote from the solid surfaces, manufactured using computer-aided design and additive manufacturing processes like 3D printing from metallic or polymeric materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional internal voids are used in surgical implant devices, then weight savings are achieved, but structural integrity and strength are compromised
Solution Approach 1:
The lattice structure employs variable strut diameters where struts adjacent to solid surfaces have smaller diameters while struts remote from solid surfaces have larger diameters. This local variation optimizes the balance between weight reduction and structural strength, allowing weight savings without compromising integrity.
Solution Approach 2:
The invention integrates multiple materials including metallic materials (titanium, stainless steel) and polymeric materials (PEEK) within a single lattice structure. This composite approach enables weight reduction through material selection while maintaining structural integrity through the combination of different material properties.
2Weight of moving object
If conventional internal voids are used in surgical implant devices, then weight savings are achieved, but elasticity is insufficient
Solution Approach 1:
The lattice structure employs variable strut diameters where struts adjacent to solid surfaces have smaller diameters while struts remote from solid surfaces have larger diameters. This local variation optimizes the balance between weight reduction and structural strength, allowing weight savings without compromising integrity.
Solution Approach 2:
The invention changes the geometric parameters of the lattice structure, specifically the strut diameters and void sizes, to optimize elasticity. The variable diameter design creates regions of different stiffness that work together to provide superior elastic properties while maintaining weight reduction.
3Ease of manufacture
If conventional internal voids are used in surgical implant devices, then manufacturing is simplified, but bony ingrowth and purchase are inadequate
Solution Approach 1:
The lattice structure creates an interconnected porous network with controlled pore sizes and distributions that promote bone ingrowth. The porous architecture provides surface area for bone attachment and integration while maintaining structural integrity.
Solution Approach 2:
The lattice structure employs variable strut diameters where struts adjacent to solid surfaces have smaller diameters while struts remote from solid surfaces have larger diameters. This local variation optimizes the balance between weight reduction and structural strength, allowing weight savings without compromising integrity.
4Ease of manufacture
If uniform strut diameters are used throughout the lattice structure, then manufacturing is easier, but structural integrity is compromised
Solution Approach 1:
The lattice structure employs variable strut diameters where struts adjacent to solid surfaces have smaller diameters while struts remote from solid surfaces have larger diameters. This local variation optimizes the balance between weight reduction and structural strength, allowing weight savings without compromising integrity.
Data Source
AI summary
A surgical implant device includes opposing first and second solid surfaces and a third solid surface connecting the first solid surface and the second solid surface. The third solid surface includes a hole penetrating through the first and second solid surfaces. The hole includes an outer surface with a first region and an inner surface. A surface roughness of the first region is greater than a surface roughness of the inner surface.