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RAPID MANUFACTURING SYSTEM OF ORTHOPEDIC IMPLANTS
Carlos Relvas1, Joana Reis2, José Alberto Caeiro Potes3
1PhD, Assistant Professor, Department of Mechanical Engineering, University of Aveiro, Portugal.
Revista Brasileira De Ortopedia
|March 23, 2016
Summary
This study developed a rapid orthopedic implant manufacturing method using in situ geometry capture and CNC machining. This innovation enables custom implant creation during surgery, reducing procedure time.
Area of Science:
- Biomedical Engineering
- Orthopedic Surgery
- Materials Science
Background:
- Current orthopedic implant procedures often require significant lead time for custom fabrication.
- The need for anatomically adapted implants and bone defect reconstruction necessitates efficient manufacturing solutions.
- Simultaneous implant production with surgical intervention remains a significant challenge in orthopedics.
Purpose of the Study:
- To develop a methodology for the rapid, in situ manufacture of orthopedic implants.
- To create patient-specific implants adaptable for bone replacement and anatomical fit.
- To integrate implant fabrication seamlessly within the surgical workflow.
Main Methods:
- Utilized direct shape capture with an elastomeric material (polyvinylsiloxane) for precise in situ geometry acquisition.
- Employed CAD/CAM systems and CNC milling for implant fabrication from the captured geometry.
- Tested the developed system in an in vivo sheep hip arthroplasty model.
Main Results:
- Achieved rapid manufacturing of orthopedic implants within a timeframe compatible with surgical procedures.
- Demonstrated the feasibility of creating anatomically adapted implants and bone loss replacement solutions.
- The in vivo test resulted in an 80-minute surgery time increase, with 40 minutes dedicated to implant manufacturing.
Conclusions:
- The developed low-cost, commercially available technology enables rapid orthopedic implant production during surgery.
- The methodology successfully meets the defined study goals for timely, patient-specific implant fabrication.
- This approach offers a viable solution for enhancing orthopedic surgical efficiency and customization.
