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US 2026/0256592 A1Published application
Anisotropic Materials in Medical Devices
AssigneeKambiz Behzadi
InventorsKambiz Behzadi, Michael E. Woods
Life of this patent
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Abstract
A system and method for improving upon an ability of a surgeon to repair traumatic bone injury using new materials, components, and structures. A structure may be used as an implant or a component of an external fixator for a fractured long bone with that structure having anisotropic and viscoelastic properties, such as through additive manufacturing techniques.
Claims29
1:
- An orthopedic implant comprising:
- a foundation including a porous or a cellular material;
- and
- a framework disposed within or on said foundation, said framework including a plurality of structural elements;
- wherein said framework and said foundation cooperatively define an anisotropic bulk material property of the implant;
- and
- wherein said framework has greater strength and fracture resistance than said foundation, and said foundation has reduced stiffness relative to said framework.
4 more elements
2-22. (canceled)
23:
- A method of manufacturing an orthopedic implant comprising:
- forming a foundation, said foundation including a porous or a cellular material;
- and
- disposing a framework within or on said foundation during manufacture, said framework including a plurality of structural elements arranged such that said framework and said foundation cooperatively define an anisotropic bulk material property of the implant;
- wherein said framework provides increased strength and resistance to fracture and said foundation provides reduced stiffness relative to said framework.
2 more elements
24:
- The method of claim 23, wherein the orthopedic implant is manufactured by additive manufacturing using single-material or multi-material additive manufacturing.
25-41. (canceled)
42:
- The implant of claim 1, wherein said framework includes a plurality of ribs and a plurality of planks.
43:
- The implant of claim 42, wherein said ribs extend generally longitudinally and said planks extend generally circumferentially within said foundation.
44:
- The implant of claim 42, wherein said ribs and planks are arranged in orthogonal patterns within said foundation.
45:
- The implant of claim 1, wherein said framework includes one-dimensional, two-dimensional, or three-dimensional structural arrangements.
46:
- The implant of claim 1, wherein said framework includes tubes, sheets, slabs, walls, beams, columns, ribs, planks, helical structures, or combinations thereof.
47:
- The implant of claim 1, wherein said framework is arranged to reinforce junction regions of said porous or cellular foundation to resist crack initiation or crack propagation at said junction regions.
48:
- The implant of claim 1, wherein said foundation includes a graded porosity, graded density, or graded material-properties profile.
49:
- The implant of claim 48, wherein said graded porosity, graded density, or graded material-properties profile varies proximodistally, peripherally-to-centrally, mediolaterally, or combinations thereof.
50:
- The implant of claim 1, wherein said framework includes a metallic material and said foundation includes the same metallic material, and said anisotropic bulk material property is produced by variation of density, porosity, crystalline structure, or microstructure of said same metallic material.
51:
- The implant of claim 1, wherein said framework includes a first metallic material and said foundation includes a second, different metallic material.
52:
- The implant of claim 1, wherein said framework includes a non-metallic reinforcement material selected from polymers, ceramics, composites, aramid fibers, carbon fibers, glass fibers, carbon nanotubes, boron nitride nanotubes, silicon carbide, graphite, or combinations thereof.
53:
- The implant of claim 1, wherein said foundation includes a non-metallic material selected from a polymer, a fiber-reinforced polymer, a composite, a ceramic, a glass-based material, or combinations thereof.
54:
- The implant of claim 1, wherein said framework and/or said foundation includes a composite material selected from a metal matrix composite, a ceramic matrix composite, a cermet, a fiber-reinforced polymer, or combinations thereof.
55:
- The implant of claim 1, wherein said framework and said foundation are co-manufactured using single-material or multi-material additive manufacturing.
56:
- The implant of claim 1, wherein said implant includes a femoral stem, an acetabular cup, or a prosthetic component for hip, shoulder, knee, or ankle arthroplasty.
57:
- The implant of claim 1, wherein said implant includes a trauma fixation implant selected from a fracture fixation plate, an intramedullary rod, and an external fixation rod.
58:
- The implant of claim 57, wherein said trauma fixation implant includes an intramedullary rod or an external fixation rod having ribs and planks disposed within a foundation of said rod.
59:
- The implant of claim 57, wherein said trauma fixation implant includes an external fixation rod configured to transmit selected combinations of compression, torsion, bending, shear, or tension to healing bone.
60:
- The implant of claim 1, wherein said framework is configured to provide greater compressive stiffness in a first region and greater tensile resistance in a second region.
61:
- The implant of claim 60, wherein said first region is medial and said second region is lateral.
62:
- The implant of claim 1, wherein said framework includes a set of counter-rotational helical elements configured to produce anisotropic stiffness.
63:
- The implant of claim 1, wherein said framework disposed within or on said foundation includes biodegradable or bioabsorbable structural elements configured to degrade in situ and thereby alter an anisotropic bulk material property or a stiffness profile of said implant after installation of the implant.
64:
- The implant of claim 1, wherein said framework disposed within or on said foundation includes robotic material elements including sensors, actuators, computation, or communication structures configured to adjust an anisotropic bulk material property or a stiffness profile of said implant in response to applied load, sensed strain, or healing status.
65:
- The implant of claim 1, wherein at least a portion of said foundation is configured to promote bone ingrowth or osseointegration.