Design and Manufacturing of Customized Implants

A process for customized implants, that minimizes bone removal while maximizing the fit and the “usability” of the implant, is developed. The process involves integrating technologies of Computed Tomography (CT), image processing, stereolithography, finite element analysis (FEA), and investment casting in the design and fabrication of a near optimal fit between the patient’s bone and the implant component. The analysis verified that the optimized interface surface produced a more even load distribution compared to the “standard” design. A conservative estimate of 40% decrease in bone removal may result following the procedure in this research.