Method for 3-d printing a custom bone graft

Abstract

A method for producing bone grafts using 3-D printing is employed using a 3-D image of a graft location to produce a 3-D model of the graft. This is printed using a 3-D printer and a printing medium that produces a porous, biocompatible, biodegradable material that is conducive to osteoinduction. For example, the printing medium may be PCL, PLLA, PGLA, or another approved biocompatible polymer. In addition such a method may be useful for cosmetic surgeries, reconstructive surgeries, and various techniques required by such procedures. Once the graft is placed, natural bone gradually replaces the graft.

What is claimed is: 
     
         1 : A method for producing a custom bone graft, comprising:
 obtaining an image of an intended graft location;   creating a digital model of said custom bone graft using said image; and   creating, using a 3-D printer said custom bone graft using a printing medium that forms a porous material with a load bearing strength comparable to bone.   
     
     
         2 : The method of  claim 1  wherein said porous material comprises collagen and bone morphogenetic proteins (BMP). 
     
     
         3 : The method of  claim 1  wherein said porous material comprises porous Poly Methyl Methacrylate (PMMA) and demineralized allograft bone matrix (DMB). 
     
     
         4 : The method of  claim 3  wherein said printing medium comprises Methyl Methacrylate (MMA), demineralized allograft bone matrix (DMB), sucrose crystals and a radical polymerization initiator. 
     
     
         5 : The method of  claim 4  wherein said radical polymerization initiator comprises benzoyl peroxide. 
     
     
         6 : The method of  claim 4  wherein said printing medium further comprises an antibiotic. 
     
     
         7 : The method of  claim 6  wherein said antibiotic consists of one of amoxicillin, doxycycline, gentamicin and clindamycin, or some combination thereof. 
     
     
         8 : The method of  claim 4  wherein said printing medium further comprises a radio-pacifier. 
     
     
         9 : The method of  claim 8  wherein said radio-pacifier consists of one of zirconium dioxide (ZrO 2 ), barium sulphate (BaSO 4 ), or any combination thereof. 
     
     
         10 : The method of  claim 1  further comprising a compound to increase the biodegradability of said printing medium consisting of cellulose acetate (CA), cellulose acetate phthalate (CAP), or a combination thereof. 
     
     
         11 : The method of  claim 1  wherein said printing medium is comprised of PCL, PLLA, PLGA, or any combination thereof. 
     
     
         13 : The method of  claim 1  wherein said printing medium is applied via a heated extrusion. 
     
     
         14 : A method for producing a custom bone graft, comprising:
 obtaining a 3-D image of an intended graft location;   creating a 3-D mesh using said 3-D image;   creating a 3-D digital model of said custom bone graft using said 3-D image; and   creating, using said 3-D digital mold, said custom bone graft,
 wherein said custom bone graft is formed from a porous, biodegradable, biocompatible material that is conducive to osteoinduction and has a load bearing strength comparable to bone. 
   
     
     
         15 : The method of  claim 14  wherein generating a 3-D digital mold of a negative mold for said custom bone graft further comprises using a 3-D printer. 
     
     
         16 : The method of  claim 14  wherein said mesh is water tight. 
     
     
         17 : The method of  claim 14  further comprising the step of:
 using said 3-D digital model to position screws in relation to anatomical structures. 
 
     
     
         18 : The method of  claim 14  further comprising the step of:
 using said 3-D digital model to overlay said 3-D mesh. 
 
     
     
         19 : The method of  claim 15  wherein said 3-D printer further comprises a heatable syringe configured to extrude the biocompatible material onto a printing surface. 
     
     
         20 : The method of  claim 19  wherein the biocompatible material is extruded with sidestepping or a rotated direction of layers onto the printing surface.