Overview

In this design project, we were tasked to design a new implant for our patient Ke Huy-Quan. Based on his systems and image indicators, we first diagnosed Ke Huy-Quan with aseptic loosening that is caused by excess wear debris. The new design should consider the form of the implant, the materials for each implant component, and modifications to surgical fixations. Together, the new design is expected to alleviate or reverse the aseptic loosening conditions and stimulate bone regeneration. Inspired by the Kugel Ball, our final design focused on reducing the friction between each component, thus decreasing wear. Incorporating the various novel materials, our design is also expected to promote osseointegration and bone regeneration.

Project Objectives

1. Diagnose our patients’ condition that Warrants Total hip Arthroplasty.
2. Design a custom hip implant for our assigned patient
3. Create a Solid Model of our Implant
4. Design a Computer Program for Analyzing Selected Design Parameters
5. Justify why and how the design meets the needs of the patient

Our Design

The Kugel Hip was inspired by the Kugel Ball as it replaces the femoral head with a perfectly spherical ball ballast enclosed by two cups. Materials such as TNTZ, porous tantalum, graphene and vitamin E highly crosslinked polyethylene are applied to various components of the implant to reduce the generation of wear debris and promote osseointegration. We also made several adjustments regarding surgical fixation to reduce the risk of infection and extend implant life. DP2 - Project Showcase

Problem Identification

Ke Huy-Quan is diagnosed with aseptic loosening secondary to osteolysis, which refers to the failure of joint prostheses without the presence of mechanical cause or infection.

🙍🏻‍♂️Patient Profile

🩺Reasoning for Diagnosis

📸X-Ray Image

📑Need Statement

My Contributions

• As for DP2, I took the role of the project manager, making the preliminary Gantt Chart and preparing an agenda for each design studio meeting. As the manager, I also assigned tasks after each scheduled weekly meeting and organized additional meetings to polish our designs. In addition, I served as the point of contact for our team.
• During the design process, I was highly engaged in the research for suitable materials for each implant component. Two of the materials used for the final design were proposed by me (TNTZ core of the femoral stem and graphene and vitamin E highly crosslinked polyethylene for the acetabular cup).
• Being part of the computing sub-team, I worked alongside Claire to create a python program that calculates the minimum stem diameter of the implant, the number of cycles before failure, and the number of years the stress reduction value exceeds the compressive strength value. Going above and beyond the requirements, we used “try statement” and “time.sleep method” to make the program more realistic. In addition, I also helped the modelling sub-team with bone measurements and gave some advice regarding modeling the implant components.
• I also took an active role in creating the poster board and finalizing the design report.

Design Process

• Milestones and Additional Worksheets

Preliminary Ideas and Design

Log Book of Additional Meetings & Discussions

Design Studio Meeting Minutes

Project Timeline

Documentations of Iterations

Individual Material Selection

Independent Research Summary

Skills Applied

Technical Skills:

🔧Autodesk Inventor & 3D Printing

📝Creating Project Gantt Chart and Planning Activities

💻Programming in Python

✏️Sketching Skills

Soft Skills:

🗣️Oral Presentation Skills

🧪Independent Research Skills

👥 Team Dynamics and Communications

🕛 Time Management

Design Report

Team27_DP2_DesignReport (1).pdf

Project Reflection

<aside> 💡 Compared to DP1, Design Project 2 was definitely more challenging and knowledge-based. In order to finalize a comprehensive and innovative project, we had to consider material selection, form and function of the implant (some bone mechanics), and surgical fixation. Nonetheless, I have developed a strong interest in material science, biomaterials. When selecting materials for the implant components, I was fascinated with different biomaterials and their interactions with osteoblast (bone growing cells). Moreover, DP2 was a great opportunity for me to practice my programming skills.

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• What I learned from the design project? 🏅
• Any failures? 😖
• Looking forward... 💨

DP2 - Project Showcase

*Cover image obtained from Unsplash database: https://unsplash.com/photos/B-t93LEzOAU?utm_source=63921&utm_medium=referral