Design for manufacturing of custom-made femoral stem using CT data and rapid prototyping technology

Abbaszadeh, Farid; Rahmati, Sadegh; Kheirollahi, Hossein; Farahmand, Farzam

doi:10.1504/ijrapidm.2011.040690

Cited by 4 publications

(5 citation statements)

References 33 publications

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“…Patient-specific modelling is demonstrated by simulators which include the ability to practice custom manufacturing implant components to fit individual patients. A model proposed by Abbaszadeh et al in 2011 [102] uses 3D data from a patient's femur CT scan to model a custom-made femoral stem based on the 3D shape of the internal cavity from CT data. Custom designed implant simulation is also demonstrated by Jun et al, (2012) [67] who developed a simulator allowing custom fit knee replacement using knee models reconstructed from 3D patient CT scans.…”

Section: Discussionmentioning

confidence: 99%

A review of virtual reality based training simulators for orthopaedic surgery

Vaughan

Dubey

Wainwright

et al. 2016

Medical Engineering & Physics

171

108

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This review presents current virtual reality based training simulators for hip, knee and other orthopaedic surgery, including elective and trauma surgical procedures. There have not been any reviews focussing on hip and knee orthopaedic simulators. A comparison of existing simulator features is provided to identify what is missing and what is required to improve upon current simulators. In total 11 total hip replacement pre-operative planning tools were analysed, plus 9 hip trauma fracture training simulators. Additionally 9 knee arthroscopy simulators and 8 other orthopaedic simulators were included for comparison. The findings are that for orthopaedic surgery simulators in general, there is increasing use of patient-specific virtual models which reduce the learning curve. Modelling is also being used for patient-specific implant design and manufacture. Simulators are being increasingly validated for assessment as well as training. There are very few training simulators available for hip replacement, yet more advanced virtual reality is being used for other procedures such as hip trauma and drilling. Training simulators for hip replacement and orthopaedic surgery in general lag behind other surgical procedures for which virtual reality has become more common. Further developments are required to bring hip replacement training simulation up to date with other procedures. This suggests there is a gap in the market for a new high fidelity hip replacement and resurfacing training simulator.

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Section: Discussionmentioning

confidence: 99%

A review of virtual reality based training simulators for orthopaedic surgery

Vaughan

Dubey

Wainwright

et al. 2016

Medical Engineering & Physics

171

108

View full text Add to dashboard Cite

show abstract

“…The traditional approach for this purpose is intra-operative contouring technique, via bending levers or pliers; this method is often criticized for its low accuracy and prolonged operation time. An attractive solution is to use the modern additive manufacturing techniques, which have the capability of fabrication of customized implants, 13,14 including patient-specific plates. 15 Another alternative, is pre-operative patient-specific contouring of plate, using a female mold fabricated by 3D printing machines, and a multi-point press forming die.…”

Section: Introductionmentioning

confidence: 99%

Effects of plate contouring quality on the biomechanical performance of high tibial osteotomy fixation: A parametric finite element study

Hayatbakhsh

Farahmand

2022

Proc Inst Mech Eng H

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Locking plates have threaded holes, in which threaded-head screws are affixed. Hence, they do not need to be in intimate contact with underlying bone to provide fixation. There are, however, reports that a large distance between the plate and the bone might cause clinical complications such as delayed union or nonunion, screw pull out, and screw and plate breakage. Considering the diversity in the capabilities and costs of different plate customization techniques, the purpose of this study was to investigate the effect of the plate contouring quality on the biomechanical performance of high tibial osteotomy (HTO) fixation. A finite element model of proximal tibia was developed in Abaqus, using the QCT data of a cadaver. The model was then subjected to open-wedge HTO (correction angle 12°) with TomoFix plate fixation. The sagittal curvature of the plate was changed parametrically to provide certain levels of geometrical fit, and the biomechanical performance parameters of fixation were assessed. Results indicated 5%, 9% and 38% increase in the stiffness of the construct, and the von Mises stress in the plate and locking screw just above the osteotomy site, respectively, when the level of fit of plate changed from 0% (initial non-contoured initial shape) to 100% (fully adapted shape). The same change decreased the pressure at the lateral hinge of the osteotomy by 61%, and the mean of the tensile stress on the screw shaft by 12%. It was concluded that the level of fit has conflicting effects on the biomechanical parameters of the HTO fixation system, that is, the structural stiffness, the pressure at the lateral hinge, the stresses in the plate and screws, and the pull out resistance of the screws. In particular, for HTO patients with high quality bone, the optimal level of fit should provide a tradeoff between these parameters.

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“…For the case of customized implants including internal self-supported structures, the inclusion of a porous structure design/selection step in the preoperative plan is fundamental. Abbaszadeh et al 30 have developed a methodology for designing customized hip implants based on bone CT-scan images and considering intramedullary and extramedullary bone portions as part of the design criteria. The intramedullary part of the implant was designed based on an accurate and detailed description of the 3D geometry of the femoral intramedullary cavity in order to improve the fit-and-fill performance of the femoral stem.…”

Section: Introductionmentioning

confidence: 99%

“…For the case of customized implants including internal self-supported structures, the inclusion of a porous structure design/selection step in the preoperative plan is fundamental. Abbaszadeh et al 30 intramedullary cavity in order to improve the fit-and-fill performance of the femoral stem. Recently, Mangano et al 31 reported a similar methodology based on CT-scan images for the fabrication of custom-made DMLS-printed subperiosteal implants, in particular for the restoration of an atrophic posterior mandible in an elderly patient.…”

Section: Introductionmentioning

confidence: 99%

Design and Fabrication of a Customized Partial Hip Prosthesis Employing CT-Scan Data and Lattice Porous Structures

et al. 2021

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As a larger elderly human population is expected worldwide in the next 30 years, the occurrence of aging-associated illnesses will also be increased. The use of prosthetic devices by this population is currently important and will be even more dramatic in the near future. Hence, the design of prosthetic devices able to reduce some of the problems associated with the use of current components, such as stress shielding, reduced mobility, infection, discomfort, etc., becomes relevant. The use of additive manufacturing (AM) and the design fabrication of self-supported cellular structures in the biomedical area have opened up important opportunities for controlling the physical and mechanical properties of hip implants, resulting in specific benefits for the patients. Different studies have reported the development of hip prosthetic designs employing AM, although there are still opportunities for improvement when it comes to customized design and tuning of the physical and mechanical properties of such implants. This work shows the design and manufacture by AM of a personalized stainless-steel partial hip implant using tomography data and self-supported triply periodic minimal surface (TPMS) cell structures; the design considers dimensional criteria established by international standards. By employing tomography data, the external dimensions of the implant were established and the bone density of a specific patient was calculated; the density and mechanical properties in compression of the implant were modulated by employing an internal gyroid-type cell structure. Using such a cell structure, the patient’s bone density was emulated; also, the mechanical properties of the implant were fine-tuned in order to make them comparable to those reported for the bone tissue replaced by the prosthesis. The implant design and manufacturing methodology developed in this work considered the clinical condition of a specific patient and can be reproduced and adjusted for different types of bone tissue qualities for specific clinical requirements.

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Design for manufacturing of custom-made femoral stem using CT data and rapid prototyping technology

Cited by 4 publications

References 33 publications

A review of virtual reality based training simulators for orthopaedic surgery

A review of virtual reality based training simulators for orthopaedic surgery

Effects of plate contouring quality on the biomechanical performance of high tibial osteotomy fixation: A parametric finite element study

Design and Fabrication of a Customized Partial Hip Prosthesis Employing CT-Scan Data and Lattice Porous Structures

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