Methods and systems for optimizing design and manufacture of implant components using solid freeform fabrication
Inventors
Miller, Bob • Hesketh, David P. • Dion, Ernest A.
Assignees
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Publication Number
US-9849019-B2
Publication Date
2017-12-26
Expiration Date
Abstract
A method of manufacturing a plurality of orthopedic implant components is provided. The method includes providing a design for a first implant component having at least one dimension that is based on patient-specific information and a design for a second implant component having at least one dimension that is based on patient specific information. A build plan is created that includes a position and orientation for at least each of the first and second implant components within a build chamber of a solid freeform fabrication machine and with respect to a platform of the build chamber. The implants included in the build plan are produced by executing a build run of the solid freeform fabrication machine based on the build plan, wherein the plurality of implant components are positioned and oriented in an interleaved build configuration according to the build plan.
Core Innovation
The patent describes a method of manufacturing a plurality of orthopedic implant components using solid freeform fabrication in which patient-specific information is used to provide a design for a first implant component and a design for a second implant component. A build plan is created that includes a position and orientation for at least each of the first and second implant components within a build chamber of a solid freeform fabrication machine and with respect to a platform of the build chamber. The implants included in the build plan are produced by executing a build run of the solid freeform fabrication machine based on the build plan.
The plurality of implant components are positioned and oriented in an interleaved build configuration according to the build plan. The interleaved configuration supports producing multiple orthopedic implant component types and/or dimensions in a single build run, including femoral implant components, and in another embodiment a femoral implant component and a tibial implant component. The approach includes virtually packing component designs into a build plan so that components do not overlap while accounting for process constraints within the build chamber and with respect to the platform.
The patent further emphasizes controlling position and orientation in the build chamber to address layer-dependent material behavior by using orientation relationships for strength-related performance. It discusses build configurations and orientation control using datum-based alignment, melt-layer alignment relative to an anatomical axis, and orientation of medial and lateral sides and side edges with respect to a platform and a virtual substrate surface.
Claims Coverage
Independent claim coverage is directed to manufacturing multiple patient-specific orthopedic implant components in a solid freeform fabrication build chamber by creating a position-and-orientation build plan and executing a build run, with the components arranged in an interleaved build configuration. The independent claims cover two inventive feature sets: a femoral-femoral pairing with different medial-lateral widths, and a femoral-tibial pairing, with dependent refinements for alignment and orientation relative to machine elements, melt layers, and medial/lateral relationships.
Interleaved build configuration for patient-specific femoral component widths
A method comprising providing patient-specific designs for a first and a second orthopedic implant component, creating a build plan with position and orientation for the first and second components within a build chamber with respect to a platform, and producing the implants by executing a build run, where the plurality of implant components are positioned and oriented in an interleaved build configuration and the first and second femoral implant components have medial-lateral widths that are different.
Interleaved build configuration for patient-specific femoral and tibial components
A method comprising providing patient-specific designs for a first and a second orthopedic implant component, creating a build plan with position and orientation for the first and second components within a build chamber with respect to a platform, and producing the implants by executing a build run, where the plurality of implant components are positioned and oriented in an interleaved build configuration, the first implant component comprises a femoral implant component, and the second implant component comprises a tibial implant component.
The independent claims cover solid freeform fabrication methods that use patient-specific design data to create a build plan and execute an SFF build run with an interleaved build configuration, including femoral-femoral different-medial-lateral-width and femoral-tibial component pairings. Dependent claim coverage further specifies alignment and orientation relative to machine components, melt layers, and medial/lateral side-edge relationships to the platform and virtual substrate surface.
Stated Advantages
Improve strength by reducing fracture risk associated with anisotropic, layer-dependent properties.
Minimize support structures and powder waste.
Enable fabrication of multiple orthopedic implant components with different dimensions in a single run.
Provide performance improvements (referenced as greater than 10%).
Documented Applications
Manufacturing patient-specific orthopedic implant components using solid freeform fabrication with interleaved build configurations.
Producing multiple femoral implant components of different medial-lateral widths within one build run by using interleaved build plans.
Producing a femoral implant component and a tibial implant component in a single build run.
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