Methods of designing high x-ray lucency lattice structures
Inventors
Jones, Christopher L. • Helmar, Ian • Diehl, Lucas • Tinley, Jason • Chappuis, Kevin D. • Sullivan, John F.
Assignees
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Publication Number
US-11253368-B2
Publication Date
2022-02-22
Expiration Date
Abstract
The biocompatible lattice structures disclosed herein with an increased or optimized lucency are prepared according to multiple methods of design disclosed herein. The methods allow for the design of a metallic material with sufficient strength for use in an implant and that remains radiolucent for x-ray imaging.
Core Innovation
The invention relates to designing a porous structure having an increased lucency property. A bulk volume comprising a plurality of repeating structures is generated in a form capable of analysis by an analysis tool, which analyzes at least one of a strut diameter, a cell height, a cell width, a cell depth, a device thickness, a device height, and a device length to determine at least one rotation angle of the bulk volume.
The bulk volume is propagated at an orientation determined at least in part by the at least one rotation angle. A uniformity of bulk thickness across the structure is calculated along a desired direction for viewing, where the desired direction corresponds to a direction along which the increased lucency property is desired, and the method iterates across rotations to identify a desired maximum uniformity of bulk thickness and captures the rotation angle at which the desired maximum uniformity occurs.
A final structure is generated based on the captured rotation angle and displayed for visualization via a visualization tool. The disclosed design principles emphasize that radiopacity becomes fully apparent only after a threshold bulk thickness is reached, motivating the use of bulk thickness uniformity in desired viewing directions, and the repeating structures include lattice/scaffold structural definitions with modified angles and segmented struts to achieve stiffness/strength while maintaining radiolucency.
The analysis further supports selecting unit cell rotations and orientations to maximize dispersion/disparity and uniformity of bulk thickness along x-ray viewing directions, with optional visualization such as 2D heat maps and optional quantification metrics such as a coefficient of determination (R2).
Claims Coverage
The provided content includes two independent claims, each covering a method of designing a porous lattice structure by selecting rotation angle(s) to control bulk-thickness uniformity along one or more desired viewing directions associated with increased lucency properties.
Rotation-angle-based porous lucency design via bulk thickness uniformity
Generating a bulk volume comprising a plurality of repeating structures capable of analysis to determine at least one rotation angle from analyzed strut/cell/device dimensions; propagating the bulk volume at the orientation associated with the rotation angle; calculating uniformity of bulk thickness along a desired direction for viewing corresponding to increased lucency; iterating across rotations to identify and capture a rotation angle yielding desired maximum uniformity; generating a final structure based on the captured rotation angle and displaying at least a portion for visualization.
Multi-direction viewing lucency design with captured rotation angle(s)
Generating a bulk volume comprising repeating structures sectioned into one or more portions corresponding to approximate dimensions of an implant type and capable of analysis to determine at least one rotation angle from analyzed strut/cell/device dimensions; propagating the bulk volume at the orientation determined by the rotation angle; calculating first and second uniformities of bulk thickness along first and second desired directions for viewing corresponding to first and second lucency properties; iterating across rotations to identify desired first and second uniformities; capturing the rotation angle at which the desired first and second uniformities occur along the respective directions; generating a final structure based on the captured rotation angle and displaying at least a portion for visualization.
Across both independent claims, the core inventive concept is selecting one or more rotation angles by analyzing lattice/porous structure dimensions and then propagating the bulk volume to maximize uniformity of bulk thickness along desired viewing directions associated with increased lucency property, including optionally addressing multiple viewing directions with corresponding lucency properties.
Stated Advantages
Increased lucency property for the porous structure.
Documented Applications
Interbody fusion implants, including example x-ray imaging embodiments demonstrating increased lucency of lattice bodies relative to radiopaque fixation hardware.
X-ray viewing-direction-based design for increased lucency property in imaging, including anterior-posterior x-ray and lateral x-ray viewing directions.
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