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Our project focuses on designing a fully absorbable cranial spring to improve surgical treatment for craniosynostosis in infants. Craniosynostosis is a congenital condition that involves the premature fusion of cranial sutures which can hinder brain development and requires surgical intervention.
Currently, spring-assisted cranioplasty uses stainless steel springs to expand the skull, but these require a second surgery for removal. This only introduces additional risks, increasing costs, and adding emotional stress for families. We are working in collaboration with Dr. Benjamin Massenburg from Rady Children’s Hospital and we are trying to eliminate the need for the second surgery by developing a biodegradable alternative that can degrade safely in the body.
We conducted a comprehensive design and testing process over a 10-week period. Through iterative CAD modeling, finite element analysis (FEA), and mechanical testing using the Instron machine,we evaluated countless spring geometries and materials. The optimal design achieved the target force range (6–10 N across a 1–3 cm compression) with a square cross-sectional geometry and a thicker U-bend compared to the original metal design.
While testing multiple FDA-approved biodegradable materials such as PCL and magnesium, the final recommendation we settled on was PLA due to its mechanical properties and ease of manufacturability. Although PLA is not absorbable within the ideal timeframe, it provided a solid foundation for structural analysis. Additionally, for future development we recommend using a PLA and PGA blend (PLGA) for improved degradation rates.
This absorbable spring design offers benefits including achieving the goal of eliminating secondary surgery, while reducing patient risk and healthcare costs, promoting environmental sustainability, and increasing accessibility of treatment. The spring also aligns with medical and engineering standards, including ISO 10993 and ASTM protocols, making it a strong candidate for future clinical application and regulatory approval.
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