Genesys Spine Introduces TiLock® Modular System for Spinal Fixation

A Revolutionary Design for Posterior Fixation

The TiLock® Modular System, designed by Genesys Spine, is a groundbreaking solution for posterior fixation in spinal surgeries. Inspired by the concept of a ball and socket, this system features a spherical snap ring in a conical pocket, creating a one-way capture mechanism. When the screw head presses on the snap ring, it expands inside the pocket, securely capturing the screw head. The snap ring wedges in the conical pocket when a force in the opposite direction is applied, preventing the screw head from disassociating. This simple yet finely honed design ensures stability and reliability in spinal fixation.

What sets the TiLock® Modular System apart from other spinal fixation systems is its unique properties. The tulip, which can be attached to the screw after implantation, creates a smaller footprint, allowing more room for the surgeon to operate. The system also features opposing angle interface set screws, breakaway towers on extended tulips, and reverse angle buttress threads that minimize tulip splay during final tightening. These innovative features provide enhanced surgical flexibility and improved patient outcomes.

The realization of the TiLock® Modular System involved a meticulous design process. The initial concept was developed using Solidworks and tested through 3D printing at a larger scale. The design was then fine-tuned using ANSYS mechanical to evaluate geometry. Once the geometry was approved, the parts were machined and tested according to ASTM 1717 and ASTM 1798 standards. The project underwent several iterations to meet tighter specifications, ensuring the final product's quality and reliability.

Technical specifications of the TiLock® Modular System include tulips with a diameter of 12.2mm, a height of 16.5mm (with tabs broken), and a width of 11.5mm. The system offers variants such as low top, reduction top, or extended top tulips. The screws are available in lengths ranging from 25mm to 60mm (up to 100mm for the 8.6mm version) and thread diameters from 4.5mm to 8.5mm in 0.5mm increments. Variants include dual-pitch/single-lead or single pitch/single-lead, cannulated or solid screws.

The TiLock® Modular System is the result of extensive research and collaboration. Genesys Spine initiates all new projects by conducting thorough research, including a review of white papers, analysis of the MAUDE database, and feedback from surgeons. Design surgeons are then selected based on their expertise and work closely with the Genesys Spine team to outline the formal design.

One of the main challenges in designing the TiLock® Modular System was creating a one-way attachment mechanism that met the design inputs. The screw needed to be polyaxial with 60 degrees of motion, have a low force requirement for attachment, and a high force requirement for separation. All of these requirements had to be met while keeping the components as small as possible. Through meticulous engineering and testing, Genesys Spine successfully overcame these challenges, resulting in a highly effective and reliable spinal fixation system.

The Genesys Spine TiLock® Modular Spinal System offers surgeons a versatile and efficient solution for posterior fixation in spinal surgeries. With its unique design, innovative features, and meticulous engineering, this system provides enhanced surgical flexibility, improved patient outcomes, and a new standard in spinal fixation.

Image Credit: J. Landon Gilkey

Awards and Accolades: The TiLock® Modular System was awarded the Iron A' Design Award in the Medical Devices and Medical Equipment Design category in 2019. This prestigious award recognizes well-designed, practical, and innovative creations that meet professional and industrial requirements. The TiLock® Modular System's integration of industry best practices, competent technical characteristics, and contribution to a better world earned it this esteemed recognition.