3D Printed Vertebral Segment with Interlocking Mechanism

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Solution Overview

Problem

Conventional vertebral bone implants often fail to match the exact size and shape of the patient's vertebrae, leading to rigidity and the need for multiple surgeries, which increases the risk of spinal injury and costs.

Innovation Solution

3D printing of implantable vertebral segments using titanium for bone members and biocompatible rubber for disc members, with an interlocking mechanism to restore flexibility and compatibility, allowing for precise customization based on patient-specific models generated through imaging techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional vertebral bone implants are used, then the surgical procedure can be performed, but the implant does not match the exact size and shape of the patient's vertebrae, leading to rigidity and the need for multiple surgeries

Engineering Contradiction:

Improvesize and shape matchVSAvoidcustomization process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Patient-specific 3D models are created from imaging data (CT or MRI scans) before the surgical procedure. This preliminary action allows the implant to be precisely customized to match the patient's anatomy, eliminating the need for intraoperative adjustments and multiple surgeries.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The implant design parameters (size, shape, geometry) are customized based on the patient's specific anatomical measurements derived from imaging data. This parameter customization ensures perfect fit while maintaining manufacturing feasibility through additive manufacturing technology.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If bone fusion is performed to correct vertebral defects, then the vertebral stability is improved, but the flexibility of the spine is compromised

Engineering Contradiction:

Improvevertebral stabilityVSAvoidspinal flexibility

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The implant provides localized stability at the defect site through the bony outgrowths that fuse with adjacent vertebrae, while the intervertebral disc component maintains flexibility in the disc space. This local differentiation allows simultaneous achievement of stability and flexibility.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The intervertebral disc component is designed to be flexible and movable, allowing natural spinal motion, while the vertebral body components provide structural stability. This dynamic design preserves spinal flexibility while ensuring vertebral stability.

Inventive Principle:

Principle #15Dynamics

3Reliability

If multiple surgeries are performed to correct vertebral defects, then the treatment can be adjusted, but the risk of spinal injury increases and costs are exponentially increased

Engineering Contradiction:

Improvetreatment adjustabilityVSAvoidspinal injury risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The implant is fully customized using patient-specific imaging data before surgery, allowing optimal treatment planning and adjustment without requiring multiple surgical interventions. This preliminary customization reduces spinal injury risk by minimizing repeated surgical exposure.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If standard artificial bone implants are used, then the surgical procedure can be completed, but the shape and size may not be correct, leading to poor results

Engineering Contradiction:

Improveimplant availabilityVSAvoidanatomical fit

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The implant parameters (dimensions, geometry, shape) are customized for each patient based on their specific anatomical measurements from imaging data. This parameter customization ensures precise anatomical fit while maintaining ease of manufacture through additive manufacturing technology.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The implant design incorporates patient-specific anatomical features and defect characteristics, creating a customized solution that matches the unique geometry of each patient's spine rather than using standardized off-the-shelf implants.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250000671A13D printing of implantable vertebral segment

Publication Date: 2025.01.02 ESTATE OF CRAIG ALAN BLANCHARD

AI summary

An implantable vertebral segment for replacing a damaged vertebral segment in a patient. The implantable vertebral segment includes a vertebral bone member and a vertebral disc member. The vertebral bone member includes an outer portion and an inner portion. The outer portion is configured to be coupled to the inner portion through a fastening mechanism, wherein the outer portion and the inner portion form a tunnel configured to receive a spinal cord. Also, the vertebral bone member and the vertebral disc member include an interlocking mechanism for coupling the vertebral bone member and the vertebral disc member.