Arthroplasty devices and related methods

• US 20080147072A1
• Filed: 12/18/2006
• Published: 06/19/2008
• Est. Priority Date: 12/18/2006
• Status: Active Grant

• Current Assignee: Howmedica Osteonics Corp. (Stryker Corporation)
• Original Assignee: Otismed Corporation (Stryker Corporation)
• Inventors: Park, Ilwhan, Chi, Charlie W.
• Granted Patent: US 8,460,302 B2
• Time in Patent Office: Days
• US Class Current: 606/87
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 17/8863 Apparatus for shaping or cutting osteosynthesis equipment by medical personnel
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

Methods and apparatuses for forming customized arthroplasty jigs are disclosed. Some of the apparatuses may comprise a plurality of rapid production machines and an automated mechanical system. The automated mechanical system may be configured to transport a first arthroplasty jig blank to a first rapid production machine and a second arthroplasty jig blank to a second rapid production machine. The first rapid production machine may be configured to form a first arthroplasty jig from the first arthroplasty jig blank, and the second rapid production machine may be configured to form a second arthroplasty jig from the second arthroplasty jig blank, the second arthroplasty jig having a different configuration from the first arthroplasty jig.

Claims

1. An apparatus configured for the production of a plurality of customized arthroplasty jigs, the apparatus comprising:

a plurality of rapid production machines; and

an automated mechanical system that is configured to transport a first arthroplasty jig blank to a first rapid production machine and a second arthroplasty jig blank to a second rapid production machine,

wherein the first rapid production machine is configured to form a first arthroplasty jig from the first arthroplasty jig blank and the second rapid production machine is configured to form a second arthroplasty jig from the second arthroplasty jig blank, and the first and second arthroplasty jigs have different configurations.

2. The apparatus of claim 1, wherein the automated mechanical system comprises a robot.

3. The apparatus of claim 1, wherein at least one of the first and second arthroplasty jig blanks is in the form of a block of material.

4. The apparatus of claim 1, wherein the rapid production machines comprise computer numerical control machines.

5. The apparatus of claim 1, wherein the apparatus comprises eight rapid production machines.

6. The apparatus of claim 1, wherein the automated mechanical system is in communication with a computer.

7. The apparatus of claim 6, wherein the computer is configured to provide the automated mechanical system with first machining instructions for forming the first arthroplasty jig.

8. The apparatus of claim 7, wherein the computer is configured to provide the automated mechanical system with second machining instructions for forming the second arthroplasty jig.

9. The apparatus of claim 8, wherein the automated mechanical system is configured to communicate the first machining instructions to the first rapid production machine.

10. The apparatus of claim 9, wherein the automated mechanical system is configured to communicate the second machining instructions to the second rapid production machine.

11. The apparatus of claim 1, wherein the apparatus is configured to produce at least 30 customized arthroplasty jigs per hour.

12. The apparatus of claim 1, wherein the rapid production machines are arranged in rows.

13. The apparatus of claim 1, wherein the rapid production machines are arranged in a circle.

14. The apparatus of claim 1, wherein the automated mechanical system is configured to remove the first arthroplasty jig from the first rapid production machine when formation of the first arthroplasty jig has been completed.

15. The apparatus of claim 14, wherein the automated mechanical system is configured to transport the first arthroplasty jig from the first rapid production machine to a station that is configured to clean arthroplasty jigs.

16. The apparatus of claim 15, wherein the station also is configured to package the arthroplasty jigs after they have been cleaned.

17. The apparatus of claim 14, wherein the automated mechanical system is configured to transport the second arthroplasty jig from the second rapid production machine when formation of the second arthroplasty jig has been completed.

18. An apparatus configured for the production of a plurality of customized arthroplasty jigs, the apparatus comprising:

a rapid production machine comprising a first component and a second component; and

an automated mechanical system that is configured to transport a first arthroplasty jig blank to the first component and a second arthroplasty jig blank to the second component,

wherein the first component is configured to form a first arthroplasty jig from the first arthroplasty jig blank and the second component is configured to form a second arthroplasty jig from the second arthroplasty jig blank, and the first and second arthroplasty jigs have different configurations.

19. The apparatus of claim 18, wherein the automated mechanical system comprises a robot.

20. The apparatus of claim 18, wherein the rapid production machine comprises a computer numerical control machine.

21. The apparatus of claim 18, wherein the automated mechanical system is in communication with a computer.

22. The apparatus of claim 21, wherein the computer is configured to provide the automated mechanical system with first machining instructions for forming the first arthroplasty jig.

23. The apparatus of claim 22, wherein the computer is configured to provide the automated mechanical system with second machining instructions for forming the second arthroplasty jig.

24. The apparatus of claim 23, wherein the automated mechanical system is configured to communicate the first machining instructions to the first component of the rapid production machine.

25. The apparatus of claim 24, wherein the automated mechanical system is configured to communicate the second machining instructions to the second component of the rapid production machine.

26. The apparatus of claim 18, wherein the apparatus is configured to produce at least 30 customized arthroplasty jigs per hour.

27. A method of manufacturing a plurality of customized arthroplasty jigs, the method comprising:

activating an automated mechanical system in an apparatus comprising the automated mechanical system and a plurality of rapid production machines, so that the automated mechanical system transports a first arthroplasty jig blank to a first rapid production machine that is configured to form a first arthroplasty jig from the first arthroplasty jig blank, and so that the automated mechanical system transports a second arthroplasty jig blank to a second rapid production machine that is configured to form a second arthroplasty jig from the second arthroplasty jig blank,

wherein the first and second arthroplasty jigs have different configurations.

28. The method of claim 27, wherein the automated mechanical system comprises a robot.

29. The method of claim 27, wherein the automated mechanical system transports the first arthroplasty jig blank to the first rapid production machine prior to transporting the second arthroplasty jig blank to the second rapid production machine.

30. The method of claim 27, wherein the first and second rapid production machines comprise computer numerical control machines.

31. The method of claim 27, wherein the apparatus comprises eight rapid production machines.

32. The method of claim 27, wherein the automated mechanical system is in communication with a computer.

33. The method of claim 32, wherein the computer provides the automated mechanical system with first machining instructions for forming the first arthroplasty jig.

34. The method of claim 33, wherein the computer provides the automated mechanical system with second machining instructions for forming the second arthroplasty jig.

35. The method of claim 34, wherein the automated mechanical system communicates the first machining instructions to the first rapid production machine so that the first rapid production machine can form the first arthroplasty jig.

36. The method of claim 35, wherein the automated mechanical system communicates the second machining instructions to the second rapid production machine so that the second rapid production machine can form the second arthroplasty jig.

37. The method of claim 27, wherein the method comprises producing at least 30 customized arthroplasty jigs per hour.

38. The method of claim 27, wherein the rapid production machines are arranged in rows.

39. The method of claim 27, wherein the rapid production machines are arranged in a circle.

40. The method of claim 27, wherein the automated mechanical system removes the first arthroplasty jig from the first rapid production machine when formation of the first arthroplasty jig has been completed.

41. The method of claim 40, wherein the automated mechanical system transports the first arthroplasty jig from the first rapid production machine to a station that is configured to clean arthroplasty jigs.

42. The method of claim 41, wherein the station also is configured to package the arthroplasty jigs after they have been cleaned.

43. The method of claim 40, wherein the automated mechanical system transports the second arthroplasty jig from the second rapid production machine when formation of the second arthroplasty jig has been completed.

44. A method of manufacturing a plurality of customized arthroplasty jigs, the method comprising:

activating an automated mechanical system in an apparatus comprising the automated mechanical system and a rapid production machine, so that the automated mechanical system transports a first arthroplasty jig blank to a first component of the rapid production machine that is configured to form a first arthroplasty jig from the first arthroplasty jig blank, and so that the automated mechanical system transports a second arthroplasty jig blank to a second component of the rapid production machine that is configured to form a second arthroplasty jig from the second arthroplasty jig blank,

wherein the first and second arthroplasty jigs have different configurations.

45. The method of claim 44, wherein the automated mechanical system comprises a robot.

46. The method of claim 44, wherein the rapid production machine comprises a computer numerical control machine.

47. The method of claim 44, wherein the automated mechanical system is in communication with a computer.

48. The method of claim 47, wherein the computer provides the automated mechanical system with first machining instructions for forming the first arthroplasty jig.

49. The method of claim 48, wherein the computer provides the automated mechanical system with second machining instructions for forming the second arthroplasty jig.

50. The method of claim 49, wherein the automated mechanical system communicates the first machining instructions to the first component of the rapid production machine so that the first component can form the first arthroplasty jig.

51. The method of claim 50, wherein the automated mechanical system communicates the second machining instructions to the second rapid production machine so that the second rapid production machine can form the second arthroplasty jig.

52. The method of claim 44, wherein the method comprises producing at least 30 customized arthroplasty jigs per hour.