Personalized orthopedic solutions through the advanced 3D CAD modeling

Client and challenge

Our client is a leading manufacturer of orthopedic solutions. They sought to optimize the design and selection of their orthopedic products, in particular, prosthetics and related surgical devices required for implantation, for improved patient-specific fit and performance.

Traditional R&D methods lacked the ability to simulate the complex interactions between implants or devices and the diverse range of human limb anatomy variations. They needed 3D models of human lower limbs that would allow them to:

• Consider anatomical variations: take into account the differences in male and female anatomy, slender and wide builds, and pediatric patients.
• Simulate material properties: use the CAD software to test different material properties for both prosthetic and surgical implantation tools to define optimal combinations for various anatomies.
• Simulate implantation scenarios: visualize and analyze interactions between surgical device and a bone or joint, or between a limb and prosthetic with the ability to change parameters on-the-go. 
• CAD compatibility: the resulting models are to be presented as CAD objects for further design with the help of the CAD software. 

Solution

To fulfill the client’s requirements, we employed advanced 3D modeling techniques. Unlike conventional hollow 3D models, we focused on creation of solid CAD objects suitable for assignment of realistic physical properties. 

The process involved the following steps:

1. Model acquisition

We began with a selection of pre-built models from the library.

2. CAD conversion

These models were converted into solid CAD objects to enable the application of material properties and make necessary adjustments before the actual production.

3. Customization

The CAD models were then modified with precision to represent the variations of human limb anatomies, including male, female, slender and wide builds as well those of pediatric patients. To guarantee anatomical accuracy, we considered specific anatomical landmarks which included different bone dimensions, axial alignment of the lower limbs, and overall limb morphology. Different material properties (e.g., density, elasticity, tensile strength) were assigned to both the prosthetic components and the surrounding tissues within the CAD environment.