3D Printing – Brett Kotlus
Abstract for “3D Design and Fabrication System for Implants”
A method for designing, presenting and generating custom implants. This involves obtaining a 3D model of a site that will receive an implant, simulating the volumetric changes at the site, creating a virtual 3D implant and then fabricating a 3D implant. This is a method for implanting a custom-made implant in a patient. It involves obtaining a 3D model of the site where the implant will be placed, simulating volumetric variations of the site, creating a virtual 3D implant and fabricating the implant in the patient. Method of correcting patient disfigurement. Method of replacing a disc on a patient’s back. This invention also allows for the fabrication of an implant using this method.
Background for “3D Design and Fabrication System for Implants”
“1. “1.
“The invention concerns methods for fabricating aesthetic and reconstructive surgical implant. The invention also relates to the creation of custom implants.
“2. Background Art”
“After severe injury or disease, the restoration of normal function, appearance, and symmetry can require surgery that involves implanting materials to reshape affected areas of the body. Implants can also be used to improve the volume and shape of normal anatomic areas of the body. Most implants that are commonly used are pre-fabricated and generic shapes. They must be as specific as possible to each person. The majority of implants are generic and can be used for any patient. They do not consider normal asymmetry or any other unique characteristics.
“There are many methods for generating implants. U.S. Pat. No. 7,747,305 to Dean, et al. This is one method to generate an implant using a 3D CT scan. The ‘305 patent describes a computer-aided design process for creating an implant for a patient before operation. It includes the following steps: Generating data from a non-invasive 3D scan of the patient’s defect area to digitally represent the area to receive the implant; validating digital data from a volume image taken of the patient; and fabricating an implant solely using the computer-generated implant design data.
“U.S. Patent Application Publication No. “U.S. Patent Application Publication No. 2006/0212158” to Miller describes a method and device for manufacturing and implanting custom subtalar arthroereisis implants with side surfaces that are mirror-like in topography with the sinuses of a patient. Images of the patient in a weight bearing position are used to create the implant. The images also include the bone structure and sinus tarsi. This 3D image can be obtained using a CAT scanner, or an MRI device. The three-dimensional printer or computer driven mill can form the implant. Implantation is painless and the implant maintains anatomically correct alignment. This minimizes patient tendency to move between the patent’s talus or calcaneus.
“U.S. Patent Application Publication No. “U.S. Patent Application Publication No. 2006/0212158 is to Feldman. It generally describes a method and device for manufacturing and implanting custom subtalar arthroereisis implants with side surfaces that are mirror-like in topography with the sinuses of a patient. Anatomically, the implant is created by images of the patient in a weight bearing position. The sinus tarsi and surrounding bone structure are aligned in the right alignment. These 3D images are possible to be obtained using a CAT scanner and MRI devices. To modify the implant, 3D modeling software can be used (Mimics Software Suite Materialise), once the image has been sent to the computer. An implant can be made using a 3-D printer or CNC machine. Implantation is painless and the implant maintains anatomical alignment. This minimizes patient tendency to move between the patent’s talus or calcaneus.
“Custom implants can also be created from MRI and CT scans, but they come with a few drawbacks. Both MRI and CT scans can be used to give radiation to patients. Implants must be manufactured off-site in a laboratory with injection molding. This can take several days to several months. You can also have unshaped materials (blocks), which are tedious and inaccurate. They are not able to visualize a simulated surgical outcome. They do not allow customization via virtual 3D photographs. They cannot visual predict the soft tissue changes that will occur after implantation.
“There is a need for an easier way to customize implants for patients, with on-site creation that takes less time than current methods.”
The present invention enables the creation, presentation, generation, and fabrication of custom implants. This is done by creating a 3D image that shows the location where an implant will be placed, simulating volumetric changes, and then creating a virtual 3D implant.
The present invention allows for the creation of a 3D model of a site that will receive an implant. This is then used to generate a virtual 3D implant.
“The invention also allows for the correction of disfigurement in patients by creating a 3D image showing a site where an implant will be placed, simulating volumetric changes, and then fabricating a 3D implant. The implant can then be implanted in the patient and the disfigurement corrected.
The present invention also provides a method for replacing a disc in a patient?s back. This is done by taking a 3D image from the back and simulating volumetric changes. Next, the virtual disc is created, then the real disc is made, and the disc is implanted in the patient’s spine.
“The invention also allows for the fabrication of an implant using this method.”
“DESCRIPTION DU DRAWINGS”
“Alternative advantages of the invention are easily appreciated when the same is referred to in conjunction with the accompanying illustrations wherein:
“FIG. “FIG.
“FIGS. “FIGS.
“FIG. 3 is an illustration of a virtual 3D implant;
“FIG. “FIG.
“FIG. FIG. 5A is an image showing a 3D printer and FIG.
“FIG. “FIG.
“FIG. “FIG.
The present invention relates to a method for designing, presenting and generating custom implants that can be used in humans. It is based on 3D imaging. This customization takes into consideration individual anatomic findings and pre-existing asymmetries. It also considers unique structures and modifications that may be desired.
“The method involves obtaining a 3D view of an area or site of the body that will receive an implant 10, simulating volumetric variations of the site 12, and creating a virtual 3D Implant 14. Finally, fabricating a 3D implant 16. These steps are shown in FIG. 7. This invention also allows for the fabrication of an implant using this method.
There are many ways to obtain a 3D image. FIG. FIG. 1 shows multiple still digital photos taken from different angles of the site or area on the patient who is to receive the implant. Multiple cameras can be used for the photos. Six digital cameras, such as the Canfield Scientific, Inc., can be used to take images of the site. You can use a 3D camera, but you can also use any other camera with software that can combine images from different angles to create a 3D image. To create a 3D image, any combination of cameras is possible. A smartphone, tablet or video camera can all be used to capture still images that can then be used to create a 3D image. A 3D scanner can also be used to scan the site for the 3D image. To capture 3D information, the 3D scanner moves around patients to capture 3D surface information. You can choose from a laser, infrared or light scanner. The 3D image can either be saved on the scanner or the camera, or sent to a computer via wired or wireless signals.
The external photo shows volumetric changes to the site or body area. (See FIGS. The patient can view 2A and 2B (with the chin area) This is best done using morphing tools on the computer. Canfield Mirror (Canfield Scientific, Inc.) or other suitable morphing program can be used as the morphing tool. One skilled in the art can calibrate these morphing tools as needed (shown at 30 in FIG. 7). You can simulate the desired implant shape using the morphing software alone. The computer software can generate the implant by simply morphing a portion of the patient’s body with the morphing software. Based on these adjustments, the computer can calculate the shape and size of the implant. Size and shape. The computer software can determine the best standard implant for you and allow you to adjust the fit using the below fabrication methods. Subtracting before and after morphing creates a difference model that is used to determine the shape and size of the implant. A completely customized implant can also be made based on the calculations. The software simulates external appearances using physics modeling and predicts the impact of the implant on surrounding structures and tissue.
“Alternatively, the morphing tool can use pre-determined implant shapes that have been preloaded in the software and can be modified after simulated surgery (shown at 18 in FIG. 7). A standard implant shape can be used as the starting point to morph the patient’s body. The 3D image can then be modified to modify the standard implant shape and create the desired result for the patient. You can make modifications to the standard implant’s anterior surface, but the posterior surface will remain the same. curvature. The software simulates external appearance using physics modeling and predicts the effect of the implant on surrounding structures and tissue.
“Regardless of whether the patient’s body has been morphed from the software or a standard implant is selected and subsequently adjusted,” the present invention is more advantageous than methods in the prior arts because the patient can see the result from the morphed 3D model and can decide whether or not they find it acceptable. Adjustments can also be made in real-time until they are happy and approve the morphed 3D picture.
Another option is to use a CT/MRI image to obtain an externally-captured image of the patient and the 3D image to determine its anterior surface. A 3D CT image can be used to align the 3D photographic image with the 3D CT image (shown 20 in FIG. 7), so both images can be used simultaneously to examine how the implant interacts and interacts with the bone. You can also capture internal images using CT, MRI or cone beam scan. These images can be used to help you obtain an image of your site. All of these images can be combined and aligned together (i.e. External images can be merged and aligned to internal images, etc.
“The morphing tools may also allow for complete customization using bulge or warp tools to modify 3D external images. An implant can be made based on the calculated difference volume between original and morphed images. The isolated difference model can be modified further.”
“Next, a virtual 3D Implant is created by a computer software program that achieves desired volume and contour changes, as shown in FIG. 3. The software tool used in this step can be the same or any other software. The 3D implant can be viewed in the software. Adjustments and refinements can then be made to the dimensions. These measurements will then be compared against 3D images of the patient to create the final design. FIG. 4 and 22 in FIG. 7. At this stage, any desired changes, including, but not restricted to, shape, dimensions, edges, size and projection, can be made. The implant can then be?re-simulated’ after the refinements and changes have been made. The original presurgical image was shown to the patient. You can make further adjustments using the morphing tools. The patient can continue to refine the process until they are satisfied with the final implant. The 3D virtual implant and any other information are saved on computer-readable media, preferably as a CAD file. The file is sent via wired or wireless communication to the fabrication machine.
The implant can now be made with acrylic or plastic for testing purposes before final production. The surrounding tissue/structures/skeleton of the patient can also be fabricated in synthetic material for use in pre-surgical and/or intraoperative planning. These steps can be done with a CNC machine or a 3D-printer.
“The 3D real implant is made from the virtual 3D implant using a biocompatible material and the fabrication machine. The present invention uses computer software to control robotics to create an implant. A 3D printer (FIG. 5A, 24 in FIG. 7) or a CNC machine. 5B, 26 in FIG. 7). The additive manufacturing process is used by a 3D printer to create the 3D implant. The CNC machine uses a subtractive process to directly carve or mill the material to create the 3D implant. The negative image can also be used to make a mold, which is then injected with the material. The implant can be made directly at a doctor’s office using a 3D printer/CNC. FIG. 6 shows a finished, fabricated implant. 6.”
“The materials that can be used can be, but are not limited to, silicone, hard silicone, polymethylmethacrylate (PMMA), porous polyethylene, polytetrafluoroethylene (PTFE), titanium, and hydroxylapatite. Materials that can be used to stimulate cell growth and ingrowth include a bioscaffold, collagen matrix, synthetic live material, bioscaffold or printed live tissue (see FIG. 28). 7).”
“After fabrication, the implant may be sterilized or prepared for implantation in the patient.”
The present invention is applicable to any part of the body that needs an implant. It can be used, for example, on the face (chin and cheek, nose, temples, brows, tear troughs, orbital rims, orbit, mandible or skull). The body (the knees and elbows, chest, breasts, buttocks and calf), ), or skeletal. (joints, spines, back, etc. Particularly, the FIGURES show a chin-implant example.
The present invention is applicable to many applications in which implants are needed or desired, for both aesthetic and functional reasons. This method can be used to treat disfigurement regardless of whether it is due to an accident or disease. This method can also be used to improve physical features.
“The present invention is most commonly used to implant a custom-made implant in a patient. It involves obtaining a 3D model of the area where the implant will be placed, simulating volumetric changes at the site, creating a virtual 3D implant and then implanting it in the patient.
“The invention also allows for the correction of disfigurement in patients by creating a 3D image showing a site where an implant will be placed, simulating volumetric changes, and then fabricating a 3D implant. The implant can then be implanted in the patient and the disfigurement corrected.
A disc replacement for the back is another example of an implant that can also be made from this method. This method allows a standard disc to be customized to fit the patient in a custom fit to increase the intervertebral space. You can also make a custom-made implant using the same steps.
“The present invention allows for the replacement of a disc in a patient?s back. This is done by creating a 3D image from the back and simulating volumetric changes. The disc can then be made virtual, and the disc implanted in the patient’s spine.
The present invention has many advantages. This new method is able to create customized implants in hours instead of days or even weeks. This method allows the doctor to see the impact of the implant on soft tissues and how the patient will care for it. It can predict how skin, fat, and other soft tissues will look after the volume modification. The patient also gets a simulation of their exterior appearance. The physician can also morph the patient’s external appearance to create the appropriate implant, rather than guessing what the patient will look like by altering the skeletal structure. The procedure does not require radiation to the patient, unless it is combined with a CT scan. It is also much cheaper and faster than other methods.
“Throughout the application, various publications, which include United States patents are referenced by author, year, and patent number. Below are full citations of the publications. This application incorporates the entire disclosures from these patents and publications in its entirety. It does so in order to better describe the state-of-the art to which the invention pertains.
“The invention has been described in an illustrated manner. It is to be understood, however, that the terminology used is in the nature words of description and not limitation.”
“Obviously, there are many modifications and variations that can be made to the present invention based on the above teachings. The appended claims allow for the practice of the invention in other ways than what is described.
Summary for “3D Design and Fabrication System for Implants”
“1. “1.
“The invention concerns methods for fabricating aesthetic and reconstructive surgical implant. The invention also relates to the creation of custom implants.
“2. Background Art”
“After severe injury or disease, the restoration of normal function, appearance, and symmetry can require surgery that involves implanting materials to reshape affected areas of the body. Implants can also be used to improve the volume and shape of normal anatomic areas of the body. Most implants that are commonly used are pre-fabricated and generic shapes. They must be as specific as possible to each person. The majority of implants are generic and can be used for any patient. They do not consider normal asymmetry or any other unique characteristics.
“There are many methods for generating implants. U.S. Pat. No. 7,747,305 to Dean, et al. This is one method to generate an implant using a 3D CT scan. The ‘305 patent describes a computer-aided design process for creating an implant for a patient before operation. It includes the following steps: Generating data from a non-invasive 3D scan of the patient’s defect area to digitally represent the area to receive the implant; validating digital data from a volume image taken of the patient; and fabricating an implant solely using the computer-generated implant design data.
“U.S. Patent Application Publication No. “U.S. Patent Application Publication No. 2006/0212158” to Miller describes a method and device for manufacturing and implanting custom subtalar arthroereisis implants with side surfaces that are mirror-like in topography with the sinuses of a patient. Images of the patient in a weight bearing position are used to create the implant. The images also include the bone structure and sinus tarsi. This 3D image can be obtained using a CAT scanner, or an MRI device. The three-dimensional printer or computer driven mill can form the implant. Implantation is painless and the implant maintains anatomically correct alignment. This minimizes patient tendency to move between the patent’s talus or calcaneus.
“U.S. Patent Application Publication No. “U.S. Patent Application Publication No. 2006/0212158 is to Feldman. It generally describes a method and device for manufacturing and implanting custom subtalar arthroereisis implants with side surfaces that are mirror-like in topography with the sinuses of a patient. Anatomically, the implant is created by images of the patient in a weight bearing position. The sinus tarsi and surrounding bone structure are aligned in the right alignment. These 3D images are possible to be obtained using a CAT scanner and MRI devices. To modify the implant, 3D modeling software can be used (Mimics Software Suite Materialise), once the image has been sent to the computer. An implant can be made using a 3-D printer or CNC machine. Implantation is painless and the implant maintains anatomical alignment. This minimizes patient tendency to move between the patent’s talus or calcaneus.
“Custom implants can also be created from MRI and CT scans, but they come with a few drawbacks. Both MRI and CT scans can be used to give radiation to patients. Implants must be manufactured off-site in a laboratory with injection molding. This can take several days to several months. You can also have unshaped materials (blocks), which are tedious and inaccurate. They are not able to visualize a simulated surgical outcome. They do not allow customization via virtual 3D photographs. They cannot visual predict the soft tissue changes that will occur after implantation.
“There is a need for an easier way to customize implants for patients, with on-site creation that takes less time than current methods.”
The present invention enables the creation, presentation, generation, and fabrication of custom implants. This is done by creating a 3D image that shows the location where an implant will be placed, simulating volumetric changes, and then creating a virtual 3D implant.
The present invention allows for the creation of a 3D model of a site that will receive an implant. This is then used to generate a virtual 3D implant.
“The invention also allows for the correction of disfigurement in patients by creating a 3D image showing a site where an implant will be placed, simulating volumetric changes, and then fabricating a 3D implant. The implant can then be implanted in the patient and the disfigurement corrected.
The present invention also provides a method for replacing a disc in a patient?s back. This is done by taking a 3D image from the back and simulating volumetric changes. Next, the virtual disc is created, then the real disc is made, and the disc is implanted in the patient’s spine.
“The invention also allows for the fabrication of an implant using this method.”
“DESCRIPTION DU DRAWINGS”
“Alternative advantages of the invention are easily appreciated when the same is referred to in conjunction with the accompanying illustrations wherein:
“FIG. “FIG.
“FIGS. “FIGS.
“FIG. 3 is an illustration of a virtual 3D implant;
“FIG. “FIG.
“FIG. FIG. 5A is an image showing a 3D printer and FIG.
“FIG. “FIG.
“FIG. “FIG.
The present invention relates to a method for designing, presenting and generating custom implants that can be used in humans. It is based on 3D imaging. This customization takes into consideration individual anatomic findings and pre-existing asymmetries. It also considers unique structures and modifications that may be desired.
“The method involves obtaining a 3D view of an area or site of the body that will receive an implant 10, simulating volumetric variations of the site 12, and creating a virtual 3D Implant 14. Finally, fabricating a 3D implant 16. These steps are shown in FIG. 7. This invention also allows for the fabrication of an implant using this method.
There are many ways to obtain a 3D image. FIG. FIG. 1 shows multiple still digital photos taken from different angles of the site or area on the patient who is to receive the implant. Multiple cameras can be used for the photos. Six digital cameras, such as the Canfield Scientific, Inc., can be used to take images of the site. You can use a 3D camera, but you can also use any other camera with software that can combine images from different angles to create a 3D image. To create a 3D image, any combination of cameras is possible. A smartphone, tablet or video camera can all be used to capture still images that can then be used to create a 3D image. A 3D scanner can also be used to scan the site for the 3D image. To capture 3D information, the 3D scanner moves around patients to capture 3D surface information. You can choose from a laser, infrared or light scanner. The 3D image can either be saved on the scanner or the camera, or sent to a computer via wired or wireless signals.
The external photo shows volumetric changes to the site or body area. (See FIGS. The patient can view 2A and 2B (with the chin area) This is best done using morphing tools on the computer. Canfield Mirror (Canfield Scientific, Inc.) or other suitable morphing program can be used as the morphing tool. One skilled in the art can calibrate these morphing tools as needed (shown at 30 in FIG. 7). You can simulate the desired implant shape using the morphing software alone. The computer software can generate the implant by simply morphing a portion of the patient’s body with the morphing software. Based on these adjustments, the computer can calculate the shape and size of the implant. Size and shape. The computer software can determine the best standard implant for you and allow you to adjust the fit using the below fabrication methods. Subtracting before and after morphing creates a difference model that is used to determine the shape and size of the implant. A completely customized implant can also be made based on the calculations. The software simulates external appearances using physics modeling and predicts the impact of the implant on surrounding structures and tissue.
“Alternatively, the morphing tool can use pre-determined implant shapes that have been preloaded in the software and can be modified after simulated surgery (shown at 18 in FIG. 7). A standard implant shape can be used as the starting point to morph the patient’s body. The 3D image can then be modified to modify the standard implant shape and create the desired result for the patient. You can make modifications to the standard implant’s anterior surface, but the posterior surface will remain the same. curvature. The software simulates external appearance using physics modeling and predicts the effect of the implant on surrounding structures and tissue.
“Regardless of whether the patient’s body has been morphed from the software or a standard implant is selected and subsequently adjusted,” the present invention is more advantageous than methods in the prior arts because the patient can see the result from the morphed 3D model and can decide whether or not they find it acceptable. Adjustments can also be made in real-time until they are happy and approve the morphed 3D picture.
Another option is to use a CT/MRI image to obtain an externally-captured image of the patient and the 3D image to determine its anterior surface. A 3D CT image can be used to align the 3D photographic image with the 3D CT image (shown 20 in FIG. 7), so both images can be used simultaneously to examine how the implant interacts and interacts with the bone. You can also capture internal images using CT, MRI or cone beam scan. These images can be used to help you obtain an image of your site. All of these images can be combined and aligned together (i.e. External images can be merged and aligned to internal images, etc.
“The morphing tools may also allow for complete customization using bulge or warp tools to modify 3D external images. An implant can be made based on the calculated difference volume between original and morphed images. The isolated difference model can be modified further.”
“Next, a virtual 3D Implant is created by a computer software program that achieves desired volume and contour changes, as shown in FIG. 3. The software tool used in this step can be the same or any other software. The 3D implant can be viewed in the software. Adjustments and refinements can then be made to the dimensions. These measurements will then be compared against 3D images of the patient to create the final design. FIG. 4 and 22 in FIG. 7. At this stage, any desired changes, including, but not restricted to, shape, dimensions, edges, size and projection, can be made. The implant can then be?re-simulated’ after the refinements and changes have been made. The original presurgical image was shown to the patient. You can make further adjustments using the morphing tools. The patient can continue to refine the process until they are satisfied with the final implant. The 3D virtual implant and any other information are saved on computer-readable media, preferably as a CAD file. The file is sent via wired or wireless communication to the fabrication machine.
The implant can now be made with acrylic or plastic for testing purposes before final production. The surrounding tissue/structures/skeleton of the patient can also be fabricated in synthetic material for use in pre-surgical and/or intraoperative planning. These steps can be done with a CNC machine or a 3D-printer.
“The 3D real implant is made from the virtual 3D implant using a biocompatible material and the fabrication machine. The present invention uses computer software to control robotics to create an implant. A 3D printer (FIG. 5A, 24 in FIG. 7) or a CNC machine. 5B, 26 in FIG. 7). The additive manufacturing process is used by a 3D printer to create the 3D implant. The CNC machine uses a subtractive process to directly carve or mill the material to create the 3D implant. The negative image can also be used to make a mold, which is then injected with the material. The implant can be made directly at a doctor’s office using a 3D printer/CNC. FIG. 6 shows a finished, fabricated implant. 6.”
“The materials that can be used can be, but are not limited to, silicone, hard silicone, polymethylmethacrylate (PMMA), porous polyethylene, polytetrafluoroethylene (PTFE), titanium, and hydroxylapatite. Materials that can be used to stimulate cell growth and ingrowth include a bioscaffold, collagen matrix, synthetic live material, bioscaffold or printed live tissue (see FIG. 28). 7).”
“After fabrication, the implant may be sterilized or prepared for implantation in the patient.”
The present invention is applicable to any part of the body that needs an implant. It can be used, for example, on the face (chin and cheek, nose, temples, brows, tear troughs, orbital rims, orbit, mandible or skull). The body (the knees and elbows, chest, breasts, buttocks and calf), ), or skeletal. (joints, spines, back, etc. Particularly, the FIGURES show a chin-implant example.
The present invention is applicable to many applications in which implants are needed or desired, for both aesthetic and functional reasons. This method can be used to treat disfigurement regardless of whether it is due to an accident or disease. This method can also be used to improve physical features.
“The present invention is most commonly used to implant a custom-made implant in a patient. It involves obtaining a 3D model of the area where the implant will be placed, simulating volumetric changes at the site, creating a virtual 3D implant and then implanting it in the patient.
“The invention also allows for the correction of disfigurement in patients by creating a 3D image showing a site where an implant will be placed, simulating volumetric changes, and then fabricating a 3D implant. The implant can then be implanted in the patient and the disfigurement corrected.
A disc replacement for the back is another example of an implant that can also be made from this method. This method allows a standard disc to be customized to fit the patient in a custom fit to increase the intervertebral space. You can also make a custom-made implant using the same steps.
“The present invention allows for the replacement of a disc in a patient?s back. This is done by creating a 3D image from the back and simulating volumetric changes. The disc can then be made virtual, and the disc implanted in the patient’s spine.
The present invention has many advantages. This new method is able to create customized implants in hours instead of days or even weeks. This method allows the doctor to see the impact of the implant on soft tissues and how the patient will care for it. It can predict how skin, fat, and other soft tissues will look after the volume modification. The patient also gets a simulation of their exterior appearance. The physician can also morph the patient’s external appearance to create the appropriate implant, rather than guessing what the patient will look like by altering the skeletal structure. The procedure does not require radiation to the patient, unless it is combined with a CT scan. It is also much cheaper and faster than other methods.
“Throughout the application, various publications, which include United States patents are referenced by author, year, and patent number. Below are full citations of the publications. This application incorporates the entire disclosures from these patents and publications in its entirety. It does so in order to better describe the state-of-the art to which the invention pertains.
“The invention has been described in an illustrated manner. It is to be understood, however, that the terminology used is in the nature words of description and not limitation.”
“Obviously, there are many modifications and variations that can be made to the present invention based on the above teachings. The appended claims allow for the practice of the invention in other ways than what is described.
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