Implant Device and Method for Manufacture

• US 20080195216A1
• Filed: 02/14/2008
• Published: 08/14/2008
• Est. Priority Date: 05/25/2001
• Status: Active Grant

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Philipp, Lang
• Granted Patent: US 8,617,242 B2
• Time in Patent Office: Days
• US Class Current: 623/18.11
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• CPC Class Codes: A61F 2/30942 for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3804 for elbows
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/40 for shoulders
• CPC Class Codes: A61F 2/4202 for ankles
• CPC Class Codes: A61F 2/4225 for feet, e.g. toes
• CPC Class Codes: A61F 2/4241 for hands, e.g. fingers
• CPC Class Codes: A61F 2/4261 for wrists
• CPC Class Codes: A61F 2/44 for the spine, e.g. vertebrae, spinal discs
• CPC Class Codes: A61F 2002/30092 using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2002/30884 Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/30892 parallel
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/3097 using laser
• CPC Class Codes: A61F 2210/0014 : using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2310/00011 : Metals or alloys
• CPC Class Codes: A61F 2310/00017 : Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00161 : Carbon; Graphite
• CPC Class Codes: A61F 2310/00167 : Diamond or diamond-like carbon
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00203 : containing alumina or aluminium oxide
• CPC Class Codes: A61F 2310/00239 : containing zirconia or zirconium oxide ZrO2
• CPC Class Codes: B23P 19/04 : for assembling or disassembling parts
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: G06F 30/00 : Computer-aided design [CAD]
• CPC Class Codes: Y10T 29/49995 : Shaping one-piece blank by removing material

Abstract

A knee implant includes a femoral component having first and second femoral component surfaces. The first femoral component surface is for securing to a surgically prepared compartment of a distal end of a femur. The second femoral component surface is configured to replicate the femoral condyle. The knee implant further includes a tibial component having first and second tibial component surfaces. The first tibial component surface is for contacting a proximal surface of the tibia that is substantially uncut subchondral bone. At least a portion of the first tibial component surface is a mirror image of the proximal tibial surface. The second tibial component surface articulates with the second femoral component surface.

Claims

1. A method for making an implant suitable for a joint, the method comprising:

a. providing a blank with at least one dimension larger than the implant; and

b. cutting the blank with a laser so as to form surface detail of the implant.

2. The method according to claim 1, wherein the blank is made of at least one of a polymer, a metal, a cross-linked polymer, a ceramic, a ceramic-metal composite, and an alloy.

3. The method according to claim 1, wherein providing the blank includes forming the blank by casting, milling, forging, compression molding, extruding or injection molding.

4. The method according to claim 1, further comprising determining a three-dimensional shape of at least one surface of the joint.

5. The method according to claim 4, wherein cutting the blank includes cutting the blank such that at least one surface of the implant is a mirror image of the at least one surface of the joint.

6. The method according to claim 4, wherein determining the three-dimensional shape includes imaging.

7. The method according to claim 6, wherein the imaging includes at least one of MRI, CT, ultrasound, digital tomosynthesis, and optical coherence.

8. The method according to claim 1, wherein the implant includes one of a cartilage repair implant, a unicompartmental knee implant, a bicompartmental knee implant, a total knee replacement implant, a hip implant, and a shoulder implant.

9. The method according to claim 1, wherein the implant is an interpositional joint implant.

10. The method according to claim 1, wherein the interpositional joint implant is associated with one of a knee, hip and shoulder.

11. A method for making an implant suitable for a joint, the method comprising:

a. providing a blank with at least one dimension smaller than the implant; and

b. adding material to the blank so as to form surface detail on the implant.

12. The method according to claim 11, wherein adding material to the block includes at least one of laser sintering and electron beam melting.

13. The method according to claim 11, wherein adding material to the block includes adding at least one of a ceramic, a metal and a ceramic-metal composite.

14. The method according to claim 11, further comprising, after adding material, polishing the material added to the blank.

15. The method according to claim 11, wherein the blank is made of at least one of a polymer, a metal, a cross-linked polymer, a ceramic, a ceramic-metal composite, and an alloy.

16. The method according to claim 11, wherein providing the blank includes forming the blank casting, milling, forging, compression molding, extruding or injection molding.

17. The method according to claim 11, further comprising determining a three-dimensional shape of at least one surface of the joint.

18. The method according to claim 17, wherein material is added to the blank such that at least one surface of the implant is a mirror image of at least one surface of the joint.

19. The method according to claim 17, wherein determining the three-dimensional shape includes imaging.

20. The method according to claim 19, wherein the imaging includes at least one of MRI, CT, ultrasound, digital tomosynthesis, and optical coherence.

21. The method according to claim 11, wherein the implant includes one of a cartilage repair implant, a unicompartmental knee implant, a bicompartmental knee implant, a total knee replacement implant, a hip implant, and a shoulder implant.

22. The method according to claim 11, wherein the implant is an interpositional joint implant.

23. The method according to claim 22, wherein the interpositional joint implant is associated with one of a knee, hip and shoulder.

24. A method for making an implant suitable for a joint, the method comprising:

a. providing a blank having at least one dimension that is different from the implant; and

b. modifying the blank using at least, in part, one of a laser and electron beam melting to form the implant.

25. The method according to claim 24, wherein providing the blank includes providing a blank having at least one dimension that is larger than the implant, and wherein modifying the blank includes cutting the blank with the laser.

26. The method according to claim 25, wherein modifying the blank includes polishing surfaces cut by the laser.

27. The method according to claim 24, wherein providing the blank includes providing a blank that has at least one dimension that is smaller than the implant, and wherein modifying the blank includes adding material by one of laser sintering and electron beam melting.

28. The method according to claim 27, wherein modifying the blank includes polishing the added material.

29. The method according to claim 24, wherein the blank is made of at least one of a polymer, a metal, a cross-linked polymer, a ceramic, a ceramic-metal composite, and an alloy.

30. The method according to claim 24, wherein providing the blank includes forming the blank by casting, milling, forging, compression molding, extruding or injection molding.

31. The method according to claim 24, further comprising determining a three-dimensional shape of at least one surface of the joint.

32. The method according to claim 31, wherein the blank is modified such that at least one surface of the implant is a mirror image of the at least one surface of the joint.

33. The method according to claim 31, wherein determining the three-dimensional shape includes imaging.

34. The method according to claim 32, wherein the imaging includes at least one of MRI, CT, ultrasound, digital tomosynthesis, and optical coherence.

35. A knee implant comprising:

a. a femoral component including;

i. a first femoral component surface for securing to a surgically prepared compartment of a distal end of a femur; and

ii. a second femoral component surface configured to replicate the femoral condyle; and

b. a tibial component including;

i. a first tibial component surface for contacting a proximal surface of the tibia that is substantially uncut subchondral bone, wherein at least a portion of the first tibial component surface is a mirror image of the proximal surface; and

ii. a second tibial component surface for articulating with the second femoral component surface.

36. The knee implant according to claim 35, wherein the second femoral component surface includes at least one of a ceramic and a metal, and the second tibial component surface includes at least one of a ceramic and a metal.

37. The knee implant according to claim 36, wherein both the second femoral component surface and the second tibial surface include a metal.

38. The knee implant according to claim 36, wherein both the second femoral component surface and the second tibial surface include a ceramic.

39. The knee implant according to claim 36, wherein the second femoral component surface includes one of a ceramic and a metal, and the second tibial surface includes the other of the one of a ceramic and a metal.

40. The knee implant according to claim 36, wherein the tibial component has a thickness of 3 mm or less.

41. The knee implant according to claim 36, wherein the tibial component includes an anchoring mechanism.

42. The knee implant according to claim 41, wherein the anchoring mechanism is one of a peg and a keel.

43. The knee implant according to claim 36, wherein the implant is one of a unicompartmental knee implant, a bicompartmental knee implant, and a total knee implant.