Anisotropic Materials in Medical Devices

Abstract

A system and method for improving upon an ability of a surgeon to repair traumatic bone injury using new materials, components, and structures. A structure may be used as an implant or a component of an external fixator for a fractured long bone with that structure having anisotropic and viscoelastic properties, such as through additive manufacturing techniques.

What is claimed as new and desired to be protected by Letters Patent of the United States is: 
     
         1 . A medical device system for fixation of a fracture of a long bone fracture of a patient, comprising:
 a set of fixation rods, each fixation rod of said set of fixation rods having an asymmetrical and an anisotropic property distinct from each other fixation rod of said set of fixation rods;   each said fixation rod of said set of fixation rods configured to be releasably and replaceably affixed, in an outpatient or clinic setting, to the long bone with a set of mechanical fasteners applied to cortical bone above and below the fracture producing a particular affixed fixation rod, each said particular affixed fixation rod spanning the fracture to fix the fracture of the long bone.   
     
     
         2 . The medical device system of  claim 1  wherein each said fixation rod of said set of fixation rods includes an external fixator rod. 
     
     
         3 . The medical device system of  claim 1  wherein each said fixation rod of said set of fixation rods include a structure additively manufactured from a composite metal base and varying said metal base during an additive manufacture of said structure configured to produce said distinct asymmetrical and an anisotropic properties. 
     
     
         4 . The medical device system of  claim 3  wherein each said fixation rod of said set of fixation rods includes an external fixator rod. 
     
     
         5 . An orthopedic structure, comprising:
 a body including a foundation and a framework integrated with said foundation, said body including a set of anisotropic properties;   wherein said foundation includes a metal alloy defined by a plurality of unit cells having variable material properties.   
     
     
         6 . The orthopedic structure of  claim 5  wherein a modulus of elasticity for said foundation includes a variable bulk density of said body configured to produce a set of macroscopically transition-less, borderless changes in said modulus of elasticity varying over said body. 
     
     
         7 . The orthopedic structure of  claim 6  wherein said macroscopically transition-less, borderless changes are configured to vary of said body without macroscopic transition zones defined at transitions between sheets/sections of said body. 
     
     
         8 . The orthopedic structure of  claim 5  wherein said anisotropic properties are defined by transition less changes in modulus produced by an alteration of a set of geometric properties of a set of unit cells in a metal alloy such as by adjusting a porosity and/or a crystalline structure of said metal alloy. 
     
     
         9 . The orthopedic structure of  claim 5  wherein said anisotropic properties are defined by additive manufacturing techniques additively manufacturing other non-metal material (such as glass, carbon, high strength polymers, aramid-Kevlar, silicon carbide, fine fibers of pure carbon (graphite and carbon nanotubes, nanotubes of boron nitride as framework or reinforcement into a base foundation of the body. 
     
     
         10 . The orthopedic structure of  claim 5  wherein said body includes a rod. 
     
     
         11 . The orthopedic structure of  claim 10  wherein said rod is configured for an external fixation of a fracture of a bone. 
     
     
         12 . The orthopedic structure of  claim 5  wherein said body includes a plate. 
     
     
         13 . The orthopedic structure of  claim 12  wherein said plate is configured for a fixation of a fracture of a bone. 
     
     
         14 . The orthopedic structure of  claim 5  wherein said body includes a prosthesis. 
     
     
         15 . The orthopedic structure of  claim 14  wherein said prosthesis is configured for a press fit fixation within a cavity of a bone. 
     
     
         16 . A method for manufacturing an orthopedic structure, comprising the steps of:
 additively manufacturing a body including a foundation and a framework integrated with said foundation, said body including a set of anisotropic properties;   wherein said foundation includes a metal alloy defined by a plurality of unit cells having variable material properties.   
     
     
         17 . The method of  claim 16  wherein a modulus of elasticity for said foundation includes a variable bulk density of said body configured to produce a set of macroscopically transition-less, borderless changes in said modulus of elasticity varying over said body. 
     
     
         18 . The method of  claim 16  wherein said body includes a rod. 
     
     
         19 . The method of  claim 16  wherein said body includes a plate. 
     
     
         20 . The method of  claim 16  wherein said body includes a prosthesis.