CN105853026A - 一种个性化股骨假体及制造方法 - Google Patents
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- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
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Abstract
本发明公开了一种个性化股骨假体及制造方法,该股骨假体结构包括:髌骨关节面假体和关节面假体内的股骨关节面假体;股骨关节面假体上设有两个对称的股骨髁内凸假体;在股骨关节面假体中部表面上,阵列分布有桁架多孔结构假体;在股骨关节面假体两侧设有股骨平台假体。通过采用参数化建模方法,模型的更改不必重新设计,只需要调节输入参数就可完成,可以大大提高设计效率;由于采用参数化建模方法,可直接通过调节输入参数调节孔隙度、平均孔径、表面积体积比,以适应不同年龄段需求;由于对其进行运动仿真受力分析,可实现个性化股骨假体力学的最优分配。
Description
技术领域
本发明涉及基于3D打印的股骨假体设计与制造,尤其涉及一种个性化股骨假体及制造方法。
背景技术
由于骨疾病,骨创伤,先天性畸形等原因导致其无法正常活动,严重影响人的身心健康,甚至危及生命,则需要通过手术对其进行修复或更换。目前国内手术中所采用的植入体大部分是国外进口的产品,与中国人种的匹配程度和相似性较低,因此急需研究开发适合国人个性化医学植入的股骨假体。常规个性化植入体植入后,存在生物相容性差,容易松动的缺点。
个性化生物固定型植入体因其具有生物相容性好、力学性能优良、植入后假体松动率低的优点,逐渐开始应用。但是,现有的生物固定型植入体大多在假体表面添加加强筋之类的简单设计,成型方法采用传统的铸造,具有设计效率低、生物相容性差、易松动和难成型的缺点。
发明内容
本发明的目的在于克服上述现有技术的缺点和不足,提供一种结构强度高和成型容易的个性化股骨假体及制造方法。
本发明通过下述技术方案实现:
一种个性化股骨假体制造方法,包括如下步骤:
步骤A00:通过CT或MRT获得股骨部位的片层数据;
步骤B00:将获得的片层数据,导入mimics软件,对其进行阈值分割,区域增长对初步阈值分割蒙版上彼此不相连接的分割区域进一步细分亚组,生成新的蒙版,最后对其进行平滑、去噪等操作,获得重建后股骨三维模型;
步骤C00:将重建后股骨三维模型的点云模型导入Geomagic Studio,进行模拟切骨,提取所要部位(病患部位)的股骨轮廓曲面数据;
步骤D00:将提取的股骨轮廓曲面数据导入通用三维软件完成重建,通过Grasshopper提取切骨对应面轮廓,在切骨面生成桁架多孔结构;
步骤E00:对步骤D00桁架多孔结构进行运动仿真受力分析,根据有限元运动受力分析结果,输入调节参数实时调整,优化设计,得到三维实体模型;
步骤F00:将获得的三维实体模型,进行切片分层,路径规划,导入3D金属打印设备,完成成型;
在3D金属打印过程中,
(1)判断n与N的大小;
(2)若n<N,执行步骤F00;
(3)若n≥N,执行步骤I00;
(4)打印完毕,得到符合要求的个性化股骨假体;
其中,n≥N。
一种个性化股骨假体,该股骨假体结构包括:髌骨关节面假体400和关节面假体400内的股骨关节面假体200;股骨关节面假体200上设有两个对称的股骨髁内凸假体100;
在股骨关节面假体200中部表面上,阵列分布有桁架多孔结构假体300;在股骨关节面假体200两侧设有股骨平台假体500。
所述桁架多孔结构假体300为多层,各层中的孔为梯度孔,孔径由里到外逐渐递增。所述桁架多孔结构假体300的孔径范围为50μm-1000um;
所述桁架多孔结构假体300由支柱支撑;支柱直径范围为80μm-1000um;支柱形状为方形或圆柱形。
本发明相对于现有技术,具有如下的优点及效果:
通过采用参数化建模方法,模型的更改不必重新设计,只需要调节输入参数就可完成,可以大大提高设计效率;由于采用参数化建模方法,可直接通过调节输入参数调节孔隙度、平均孔径、表面积体积比,以适应不同年龄段需求;由于对其进行运动仿真受力分析,可实现个性化股骨假体力学的最优分配。
采用激光3D打印方法使个性化股骨假的结构不再受工艺条件的限制,对具有复杂曲面、复杂孔隙可实现直接制造;
桁架多孔结构假体的层数不再受限,可以将桁架结构中的孔设计成梯度孔。通过对植入体的参数化建模和SLM直接成型,可以大大提高设计效率、达到直接制造个性化植入体的目的,提高了使用寿命。
附图说明
图1是本发明股骨假体结构示意图一。
图2是图1立体俯视图。
图3是图2桁架多孔结构假体结构示意图。
图4是图1侧视示意图。
图5是本发明股骨假体结构示意图二。
图6是本股骨假体设计、3D打印流程图。
具体实施方式
下面结合具体实施例对本发明作进一步具体详细描述。
实施例
如图1至4所示。本发明公开了一种个性化股骨假体,该股骨假体结构包括:髌骨关节面假体400和关节面假体400内的股骨关节面假体200;股骨关节面假体200上设有两个对称的股骨髁内凸假体100;
在股骨关节面假体200中部表面上,阵列分布有桁架多孔结构假体300;在股骨关节面假体200两侧设有股骨平台假体500。
为了实现生物固定型股骨假体良好的生物相容性,防止假体松动,所述桁架多孔结构假体300为多层,各层中的孔为梯度孔,孔径由里到外逐渐递增。即靠近切骨面的孔孔径较大,靠近股骨平台500的孔孔径较小,桁架多孔结构300的孔径由里到外逐渐递增,这样可以避免“应力遮挡”,实现力的最优分配,提高股骨假体的生物相容性,防止股骨假体松动,大大延长假体的使用寿命。
所述桁架多孔结构假体300的孔径范围为50μm-1000um;
所述桁架多孔结构假体300由支柱支撑;支柱直径范围为80μm-1000um;支柱形状为方形或圆柱形。
当然,所述股骨假体的桁架多孔结构层数不受限制,可以根据实际需要而定。所述股骨假体的结构不受限制,可以按照实际需要任意设计。所述股骨假体的桁架多孔结构的形状和大小可根据实际需要设定。
激光选区熔化(Selective Laser Melting,SLM)技术亦称“金属3D打印技术”是增材制造的前沿技术,利用直径30~50微米的聚焦激光束,把金属或合金粉末选区逐层熔化,堆积成一个冶金结合、组织致密的实体,从而获得几乎任意形状、具有完全冶金结合的金属功能零件。
本发明股骨假体通过金属3D激光打印设备根据股骨假体截面轮廓数据,控制激光束选择性地熔化铺平的各层金属粉末,逐步堆叠而成。可通过如下步骤实现:
步骤A00:通过CT或MRT获得股骨部位的片层数据;
步骤B00:将获得的片层数据,导入mimics软件,对其进行阈值分割,区域增长对初步阈值分割蒙版上彼此不相连接的分割区域进一步细分亚组,生成新的蒙版,最后对其进行平滑、去噪等操作,获得重建后股骨三维模型;
步骤C00:将重建后股骨三维模型的点云模型导入Geomagic Studio,进行模拟切骨,提取所要部位(病患部位)的股骨轮廓曲面数据;
步骤D00:将提取的股骨轮廓曲面数据导入通用三维软件完成重建,通过Grasshopper提取切骨对应面轮廓,在切骨面生成桁架多孔结构;
步骤E00:对步骤D00桁架多孔结构进行运动仿真受力分析,根据有限元运动受力分析结果,输入调节参数实时调整,优化设计,得到三维实体模型;
步骤F00:将获得的三维实体模型,进行切片分层,路径规划,导入3D金属打印设备,完成成型;
在3D金属打印过程中,
(1)判断n与N的大小;
(2)若n<N,执行步骤F00;
(3)若n≥N,执行步骤I00;
(4)打印完毕,得到符合要求的个性化股骨假体;
其中,n≥N;其中,N为生物固定植入的基本要求,如力学性能,尺寸精度等;n为成型后零件的基本参数。
为了提高成型的质量,激光3D打印的粉末(CoCrMo合金粉末)原材料在加入粉料缸前需要经过过滤和烘干处理:将粉末原材料经过振动筛进行过滤,以滤除粉末原材料中的杂质;再将粉末原材料进行烘干处理,以降低粉末原材料的含氧量。
粉末原材料从激光打印设备进入打印区域可以通过供粉形式或喷粉形式实现。
为了保证股骨假体的成品质量,经激光3D打印制得的股骨假体需要经过退火、喷砂、电解抛光、镜面抛光处理,并进行消毒后即可使用。
本发明通过采用激光打印方法制得的股骨假体结构,不再受工艺条件的限制,可制得具有任意结构的股骨假体,对具有复杂曲面、复杂孔隙的股骨假体都可实现直接制造;采用激光打印方法制备,股骨假体的桁架结构层数不再受限,可以将桁架结构中的孔设计成梯度孔。
由于激光打印桁架架构支柱的形状不再受限制可以采用方形或圆柱形,灵活性较大。这样可以避免“应力遮挡”,实现力的最优分配,提高股骨假体生物相容性,防止股骨假体松动,大大延长假体的使用寿命。
如上所述,便可较好地实现本发明。
本发明的实施方式并不受上述实施例的限制,其他任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化,均应为等效的置换方式,都包含在本发明的保护范围之内。
Claims (8)
1.一种个性化股骨假体制造方法,其特征在于包括如下步骤:
步骤A00:通过CT或MRT获得股骨部位的片层数据;
步骤B00:将获得的片层数据,导入mimics软件,对其进行阈值分割,区域增长对初步阈值分割蒙版上彼此不相连接的分割区域进一步细分亚组,生成新的蒙版,获得重建后股骨三维模型;
步骤C00:将重建后股骨三维模型的点云模型导入Geomagic Studio,进行模拟切骨,提取所要部位的股骨轮廓曲面数据;
步骤D00:将提取的股骨轮廓曲面数据导入通用三维软件完成重建,通过Grasshopper提取切骨对应面轮廓,在切骨面生成桁架多孔结构;
步骤E00:对步骤D00桁架多孔结构进行运动仿真受力分析,根据有限元运动受力分析结果,输入调节参数实时调整,得到三维实体模型;
步骤F00:将获得的三维实体模型,进行切片分层,路径规划,导入3D金属打印设备,完成成型。
2.根据权利要求1所述个性化股骨假体制造方法,其特征在于:在3D金属打印过程中,
(1)判断n与N的大小;
(2)若n<N,执行步骤F00;
(3)若n≥N,执行步骤I00;
(4)打印完毕,得到符合要求的个性化股骨假体;
其中,n≥N。
3.权利要求1至2中任一项所述个性化股骨假体制造方法获得的个性化股骨假体,其特征在于,该股骨假体结构包括:
髌骨关节面假体(400)和关节面假体(400)内的股骨关节面假体(200);股骨关节面假体(200)上设有两个对称的股骨髁内凸假体(100);
在股骨关节面假体(200)中部表面上,阵列分布有桁架多孔结构假体(300);在股骨关节面假体(200)两侧设有股骨平台假体(500)。
4.根据权利要求3所述个性化股骨假体,其特征在于,所述桁架多孔结构假体(300)为多层,各层中的孔为梯度孔,孔径由里到外逐渐递增。
5.根据权利要求3所述个性化股骨假体,其特征在于,所述桁架多孔结构假体(300)的孔径范围为50μm-1000um。
6.根据权利要求3所述个性化股骨假体,其特征在于,所述桁架多孔结构假体(300)由支柱支撑。
7.根据权利要求6所述个性化股骨假体,其特征在于,所述支柱直径范围为80μm-1000um。
8.根据权利要求7所述个性化股骨假体,其特征在于,所述支柱形状为方形或圆柱形。
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