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Design and characterization of a novel permanent magnet synchronous motor used in a growing prosthesis for young patients with bone cancer

Approximately 50 child sarcomas are treated with limb salvage surgery each year in the United Kingdom. These children need an extendable implant that can be lengthened periodically to keep pace with the growth in the opposite limb. Surgically, invasive devices have been used for the past 30 years with intrinsic problems of infection and long-term recurrent trauma to the patient. To eliminate problems associated with the invasive device, a non-invasive extendable prosthesis was developed. The magnetically coupled drive technology used for this prosthesis was a synchronous motor with a gear-driven telescoping shaft. In this design the motor configuration was in two parts: a rotating magnet (rotor) that fitted inside the prosthesis where space was limited and the stator, which was an external device used to extend the prosthesis remotely as the patient grew. This compact external drive produced a focused magnetic flux that required no cooling and operated on a single-phase power supply. The extending mechanism in the implant was able to overcome up to 1300 N force, which is the tension force exerted by the soft tissues during the lengthening procedure. The device has been successfully implanted in 50 patients.