Project: Just in Time Design and Production of Customised Orthopaedic Implants

Motivation_x000D__x000D_Hip joint replacement surgery uses an artificial implant to replace the hip bone – pelvis joint. It is one of the most successful procedures in medicine because it can relieve pain and enable patients to return to productive lifestyles. However, often the need for revision arises because of loosening or wear. One way to enhance the conventional joint replacement process is to evaluate the effects of an operation prior to surgery. Decisions must be made for the correct type of implant for a specific patient, precise positioning of the implant and in general how the implant will be installed and secured to achieve the best post-operational performance. Currently, surgeons cannot address these issues except by trial and error and clinical experience, and their decisions may determine the success or failure of these operations._x000D__x000D_Using Digital Engineering Technologies, surgeons can study the outcome of a joint replacement operation in software prior to surgery and evaluate different options to find the best surgical plan for each individual. The CO regions of interest are the mechanical properties of the implant - bone system, the bone regeneration behaviour after the surgery and the development of medical techniques and protocols for the implementation of the actual surgery. In all of these cases, the shape, material and surface treatment of the implant, and therefore the manufacturing process used for its production are of utmost importance. Typical hip implants are manufactured in a broad range of shapes and sizes, in an attempt to be able to fit the extend of the human anatomy. However, severely deformed hips are not always covered by the existing implant models, e.g. in the case of abnormal bone structure or accidents. _x000D__x000D_Our approach: Just in Time Design and Production of customised Orthopaedic Implants _x000D__x000D_The project aims at developing a combined Business to Customer (B2C) and Business to Business (B2B) secure platform for just in time rapid design, simulation, engineering, manufacturing and distribution of customised orthopaedic implants. The system stakeholders fall into three categories: “customer”, “virtual surgery provider” and “implant manufacturer”._x000D__x000D_From the customer (orthopaedic clinics) point of view, the JiTMI system will be used to initiate a request for “virtual surgery trial” and/or “implant design” by providing all the necessary data: CT scans, design parameters, implant category, materials and preferred shape, time-to-patient limits etc. _x000D__x000D_The “virtual surgery service provider” will receive the request for surgery and using the JiTMI’s “Integrated Virtual Surgery” toolkit will design, simulate and propose to the doctor a specific range of customised implants fulfilling the anatomy of the patient and other defined medical, production parameters and time-to-patient limits, as well as the total costs for each solution. _x000D__x000D_Initially, in the Virtual Surgery process, the DICOM image data will be processed to achieve a 3D geometric reconstruction of the hip-femur body area and define the implant design boundaries. Using 3D simulation tools, the accurate fitting of the implant and the optimum/minimally invasive insertion path for the surgery will be calculated, along with the bio mechanical and kinematic behaviour of implant-bone system. After completing the implant selection optimization cycles, the system will export a structured “surgery planning report” for intra-operative assistance._x000D__x000D_Using the collaborative environment the doctor will select the final customised implant and initiate the phase of rapid manufacturing. The implant manufacturer will receive the selected implant geometry and using sophisticated CAM tools and standard approved techniques will produce, sterilize, certify, package and deliver the final implant to the customer.

Acronym JiTMI (Reference Number: 4262)
Duration 31/07/2008 - 31/07/2011
Project Topic The project aims at developing a combined Business to Customer (B2C) and Business to Business (B2B) secure platform for just in time rapid design, simulation, engineering, manufacturing and distribution of customised orthopaedic implants.
Project Results
(after finalisation)
Software modules for secure online communication (between surgeon, implant designer and implant manufacturer), for implant design based on DICOM data and for the automation of implant production. DTSquare's part was the production automation.
Network Eurostars
Call Eurostars Cut-Off 1

Project partner

Number Name Role Country
3 OS Orthopedic Services GmbH Partner Germany
3 DTSquare GmbH Partner Germany
3 NIKI Information Technologies and Digital Engineering Ltd Coordinator Greece