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  Digital Catalogue for Technology and Products Development


   Technology and Product Development

    Basic Information

Technology developed: A novel processing technique for the development of Acetabular cup from Ultra high molecular weight (TP19766283320)
Category: Technology Service/Know how
Details of Inventor(s):
Inventor Institution/Organization/Company Department Designation
Ashirbad Jana, S.Senthilvelan and S.Kanagaraj Indian Institute of Technology Guwahati Department of Mechanical Engineering Research Scholar, Faculty, Faculty
Technical Application Area: Healthcare
If 'Other', please specify:
Please give more details of new technical application area:
Total Hip Arthroplasty THA is a revolution for the arthritic or damaged hip treatment in which the hip joint is replaced by a prosthetic implant More than 60 percentage of the retrieved failed UHMWPE acetabular components were found to have different types of mechanical failure viz aseptic loosening fracture and wear, which led to reduce the average life of THA to 10 to 15 years Thus it is inferred that the desired mechanical integrity and quality bearing surface are not achieved with the existing manufacturing techniques used to make UHMWPE products, due to major difficulties associated with their processing Compression moulding and bulk extrusion are the techniques for making UHMWPE based products and these techniques rely on diffusion of polymer particles under simultaneous application of heat and uniaxial pressure without any bulk flow of the material leading to anisotropic characteristics with numerous flaws such as fusion defect and weak bonding Imperfect boundary diffusion leads to crack initiation and its propagation in the product Moreover machining marks were also found intact on the unworn bearing surface of some of the retrieved implants which can drastically increase the wear rate during its usage This alarming situation demands an alternative manufacturing technique for processing UHMWPE to develop a defect free acetabular cup to exploit the full potential of the polymer as a bearing material in THR The major advantages of the present invention are as follows A novel technique for processing UHMWPE with proper diffusion of polymer particles to achieve desired mechanical integrity of the material Optimized process parameters to achieve desired mechanical strength Homogeneous characteristics of the proposed product A unique processing technique for the development of Acetabular cup with desired dimensional accuracy and without any machining process Acetabular cups with inbuilt surface finish and desired bearing characteristics
Organization(s):
Indian Institute of Technology (IIT) Guwahati
Affiliated Ministry: Ministry of Education
Type of technology development: Indigenous
Does the technology help in replacing any import items currently
procured from outside India?
Yes
Does the technology have export potential? Yes
Category of Technology developed: Import Substitution
Stage of Development: Prototype Level
Please describe in detail including the TRL Level:
The developed implants are tested in vitro as per the ISO 14242-3 guidelines and they are ready for in-vivoevaluation before mass production and field test. But, as it is a bio-implant,the product needs exhaustive studies on its bio-compatibility and life. A lot of protocol and authorization process needed to be followed before the commercialization of a bio-implant. This long process needs considerable time.

    Abstract:

Applications: The proposed technique is unique in terms of its versatility. Any size of Acetabular cup, specific to the patient, can be manufactured without any machining process. The surface roughness (Ra) of the Acetabular cup was found to be significantly less than that of the commercially available products, and can be improved further. Though UHMWPE used as the acetabulum material in present study, any polymer composite or ceramic material can be processed for the purpose by the same technique. Thus, the proposed methodology would be so relevant even after advancement of biomaterials research in future.
Advantages: The UHMWPE acetabular cups are observed to have an average relative density of more than 98 percentage and Vickers hardness at the bearing surface is observed to be more than 6 Some inherent features and characteristics of the bearing surface were also investigated. Surface roughness at the inner surface of developed acetabular cup was measured using Taylor-Hobson non-contact type profilometer The Ra value of the surface was found to be 0.08 micron and 0.10 micron along the two mutually perpendicular directions. Average surface roughness of the developed Acetabular cup was significantly less compared to the Ra of 0.21 micron observed for non-worn surface of retrieved UHMWPE liners. Negative skewness of -1.156 confirmed the good bearing characteristics of the surface and the corresponding Abbott-Firestone curve revealed that the bearing surface was smooth on top and rough underneath. This type of surface, Plateau finished surface, is an ideal choice for any bearing applications, which is usually generated by honing process, but the proposed technique does not require any machining process for the same. Wear loss of the material is likely to reduce significantly due to absence of micro peaks on the bearing surface whereas, the improved lubrication control and retention are expected by the trapped lubricant in the micro valleys. This would reduce the coefficient of friction CoF between the femoral head and the acetabulum during its usage and improve the life of the implant.

    Technology Inputs:

Imported Equipment/Spare Parts:
Equipment/Spare Parts Year ITC-HS Code
Warm Isostatic press 2015-16
Indigenous Equipment/Spare Parts:
Equipment/Spare Parts Year ITC-HS Code
Sonicator 2013-14
Imported Raw Materials:
Raw Materials Year ITC-HS Code
GUR 1050 UHMWPE powder 2012-13
Indigenous Raw Materials:
Raw Materials Year ITC-HS Code
Ethanol 2015-16
Existing R&D Facilities used:
Facilities Year ITC-HS Code
Central Instruments facility, IIT Guwahati 2019-20

    R&D Investment:

R&D investment (Rs. in Lakhs):                    
Indian Source (Rs.) Foreign Source (Rs.) Year
0 0 NA

   Patents & Publications:

Patents:
Filed Patents (No.) Granted Patents (No.) Year
0 2147483647 2019-20
Publications:
Submitted (No.) Published (No.) Year
0 0 NA

    Commercialization Potential:

Who are the Potential Licensees? Zimmer Biomet DePuy Synthes Orthopedics Stryker Orthopaedics Smith & Nephew, Inc.
What commercially available products address
the same problem?
Company Product Problem Addressed
Zimmer Biomet DePuy Synthes Orthopedics Stryker Orthopaedics Smith & Nephew, Inc Total Hip arthroplasty (THA) Life of the implants are limited to 10-15 years
Would you like to develop this invention further with
corporate research support?
Yes
Would you be interested in participating in cluster based
programs for commercialization research or business
planning for your invention?
Yes
      Submitted by: Jinti Saikia Date of Submission: 5-8-2020



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