3D PRINTED METAL CORPECTOMY DEVICE WITH STRUCTURAL AND ENDPLATE LATTICE STRUCTURES

Smart overview of the Invention

The patent application describes a 3D printed metal corpectomy device designed for spinal stabilization, particularly in cervical corpectomy procedures. The device features a combination of solid and lattice structures to enhance its performance. The lattice structures, which are stochastic in nature, are integrated within the device to reduce stiffness and improve radiolucency, making post-surgical x-ray assessments more effective. Additionally, these lattice structures encourage bone ingrowth, contributing to the stability of the implant.

Structural Design

The corpectomy implant consists of several key components: an anterior volume, a posterior volume, two side volumes, an upper endplate volume, and a lower endplate volume. Each of these components incorporates a specific lattice structure with pore sizes ranging from 100 to 500 microns. The device is designed with a hollow cavity running along its axis, surrounded by these lattice-structured volumes. The endplates include anti-migration features to prevent the implant from moving once installed between the vertebrae.

Porosity and Volume Fill

The implant's various volumes have porosities ranging from 30% to 70%, with the endplate volumes generally having higher porosity than the side and anterior/posterior volumes. The volume fill percentage of these structures ranges from 50% to 99%, ensuring the implant maintains its structural integrity while allowing for bone integration. The lattice density can be uniform or gradient, depending on the specific requirements of the implant's location within the spine.

Additional Features

The design includes lateral holes in the side volumes and a threaded hole in the anterior volume for securing the implant during insertion. A solid frame may partially enclose certain volumes, providing additional support. The anti-migration features, shaped like teeth, have shallow and steep angle inclines to facilitate insertion and prevent migration. Chamfered edges at specific intersections further aid in the implant's stability and ease of insertion.

Method of Use

The method for using the implant involves inserting it between upper and lower vertebrae, ensuring the anti-migration features engage with the vertebrae surfaces. A cervical plate is then placed adjacent to the anterior volume, and bone screws are inserted to secure the implant. This method allows the implant to stabilize the spine effectively, accommodating multiple vertebral levels if necessary.