Apparatus and methods for three dimensional plasthesis prostheses

Patent metadata

Field	Value
Publication number	US-2018296367-A1
Application number	US-201615767341-A
Country	US
Kind code	A1
Filing date	Oct 14, 2016
Priority date	Oct 16, 2015
Publication date	Oct 18, 2018
Grant date	—

Abstract

A prosthesis, radiation bolus, pre-surgical model, or burn mask formed using a rapid prototyping device, such as a three-dimensional printer. In some exemplary aspects, the prosthesis includes a scaffolding and a coating at least partially covering the scaffolding. Methods and systems for forming the prosthesis, radiation bolus, pre-surgical model, or burn mask are also provided.

First claim

What is claimed is:

1 . A method of forming a prosthesis, radiation bolus, pre-surgical model, or burn mask, the method comprising:
electronically receiving data from a topographic scan of a patient; electronically designing a digital model of a prosthesis, radiation bolus, pre-surgical model, or burn mask for the patient; printing at least a portion of the prosthesis, radiation bolus, pre-surgical model, or burn mask using a rapid prototyping device based on the digital model of the prosthesis, radiation bolus, pre-surgical model, or burn mask.

2 . The method of claim 1 , further comprising electronically receiving an image related to a reference image of the patient, wherein electronically designing the digital model includes designing the prosthesis, radiation bolus, pre-surgical model, or burn mask at least partially based on the reference image of the patient.

3 . The method of claim 1 , further comprising electronically removing artifacts from the data from the topographic scan of the patient.

4 . The method of claim 1 , wherein electrically receiving data from a topographic scan of the patient further comprises capturing images of the patient from multiple angles using a photogrammetry system.

5 . The method of claim 1 , further comprising electronically receiving data from a CT scan or MRI of a patient, wherein electronically designing the digital model of the prosthesis includes designing the prosthesis at least partially based on the data from the topographic scan of the patient and the CT scan or MRI of the patient.

6 . The method of claim 1 , wherein the prosthesis, radiation bolus, pre-surgical model, or burn mask is a prosthesis including a scaffolding formed from a polymer and a coating at least partially covering the scaffolding, wherein printing includes printing the scaffolding structure for the prosthesis, and wherein the method further comprises at least partially covering the scaffolding structure with the coating.

7 . The method of claim 6 , wherein, wherein printing further includes printing a mold defining a mold cavity, the method further comprising:
positioning the scaffolding in the mold cavity; filling the mold cavity with a silicone material; and curing the silicone material to form the coating.

8 . The method of claim 1 , wherein the prosthesis, radiation bolus, pre-surgical model, or burn mask is a radiation bolus.

9 . The method of claim 1 , wherein the prosthesis, radiation bolus, pre-surgical model, or burn mask is a pre-surgical model, and the method further includes forming a surgical guide based in part on the pre-surgical model.

10 . The method of claim 1 , wherein the prosthesis, radiation bolus, pre-surgical model, or burn mask is a burn mask and wherein printing a portion of the burn mask includes printing a three-dimensional model of the topographical scan of the patient and forming a pliable plastic sheet over the three-dimensional model in a thermoforming or vacuum forming machine.

11 . A prosthesis comprising:
a scaffolding, wherein the scaffolding is formed using a rapid prototyping device; and a coating at least partially covering the scaffolding.

12 . The prosthesis of claim 11 , wherein the prosthesis is a maxillofacial prosthesis.

13 . The prosthesis of claim 11 , wherein the scaffolding comprises at least one polymer selected from the group consisting of: polylactic acid, acrylonitrile butadiene styrene, and methacrylate polymers.

14 . The prosthesis of claim 11 , wherein the prosthesis comprises a first zone and a second zone, wherein the first zone has a flexibility greater than a flexibility of the second zone, wherein the first and the second zone each have a flexibility similar to a flexibility corresponding to at least one of a bone, a muscle, skin, or fat.

15 . The prosthesis of claim 11 , wherein the prosthesis comprises a first zone including a first scaffolding and a second zone including a second scaffolding, wherein the first and second scaffolding are formed from different polymers.

16 . The prosthesis of claim 11 , wherein the scaffolding comprises a plurality of geometries selected from the group consisting of: squares, triangles, trapezoids, rectangles, parallelograms, circles, diamonds, pentagons, hexagons, octagons, heptagons, ellipse, and three-dimensional shapes formed from the forgoing.

17 . A system for forming a prosthesis, radiation bolus, pre-surgical model, or burn mask including a scaffolding formed from a polymer and a coating at least partially covering the scaffolding, the system comprising:
a scanner configured to capture topographical information relating to a patient; a design module configured for electronically designing a digital model of the prosthesis, radiation bolus, pre-surgical model, or burn mask; and a three-dimensional printer configured to print the scaffolding from the polymer based on the digital model.

18 . The system of claim 17 , wherein the scanner is selected from the group consisting of: a photogrammetry system, a CT scanner, an MRI scanner, and a no-contact laser scanner.

19 . The system of claim 17 , wherein the polymer material is selected from the group consisting of: polylactic acid, acrylonitrile butadiene styrene, and methacrylate polymers and the coating comprises a silicone material.

20 . The system of claim 17 , wherein the digital model of the prosthesis, radiation bolus, pre-surgical model, or burn mask includes a digital model of the scaffolding and a digital model of a mold, and wherein the three-dimensional printer is configured to print the scaffolding based on the digital model of the scaffolding and to print the mold based on the digital model of the mold.

Assignees

• Univ Indiana Res & Tech Corp

Inventors

• Bellicchi Travis Dean
• Wood Zebulun Maxwell
• Jacobs Cade Bradley-Thomas

Classifications

• A61F13/122

  specially adapted for the face · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• A61F2/78

  Means for protecting prostheses or for attaching them to the body, e.g. bandages, harnesses, straps, or stockings for the limb stump · CPC title

• A61F2002/5001

  Cosmetic coverings · CPC title

• A61F2/5046 Primary

  for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques · CPC title