Method And Apparatus For Manufacturing An Implant

• US 20080257363A1
• Filed: 04/16/2008
• Published: 10/23/2008
• Est. Priority Date: 04/17/2007
• Status: Abandoned Application

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: White, John R., Metzger, Robert, Salyer, Brian D., Schoenefeld, Ryan J., Kiphart, Rory, Canada, Michael
• Application Number:
  US12/103,824
• Publication Number:
  US 20080257363A1
• Time in Patent Office: Days
• US Class Current: 128/897
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• 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 2/3859 Femoral components
• CPC Class Codes: A61F 2002/30616 Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30708 Means for distinguishing between left-sided and right-sided devices, Sets comprising both left-sided and right-sided prosthetic parts
• CPC Class Codes: A61F 2002/3071 Identification means; Administration of patients
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/30953 using a remote computer network, e.g. Internet
• CPC Class Codes: A61F 2002/3096 trimmed or cut to a customised size
• CPC Class Codes: A61F 2002/4633 for selection of endoprosthetic joints or for pre-operative planning
• CPC Class Codes: A61F 2250/0084 Means for distinguishing between left-sided and right-sided devices; Sets comprising both left-sided and right-sided prosthetic parts
• CPC Class Codes: A61F 2250/0085 Identification means; Administration of patients

Abstract

An orthopedic implant manufacturing method. The method includes preparing a preliminary pre-operative surgical plan for a specific patient, communicating the plan to a surgeon of the patient, and receiving an orthopedic implant design recommendation of the surgeon. The implant design recommendation can include selecting one of first, second or third options, the first option being a patient-specific implant, the second option being a semi-custom implant, and the third option being an off-the-shelf implant. The method further includes sending a request for manufacturing the selected implant to a manufacturing center, receiving the implant, and forwarding the implant for implantation.

Claims

1. An orthopedic implant manufacturing method comprising:

preparing a preliminary pre-operative surgical plan for a specific patient;

communicating the plan to a surgeon of the patient;

receiving an orthopedic implant design recommendation of the surgeon, the implant design recommendation selecting one of first, second or third options, the first option being a patient-specific implant, the second option being a semi-custom implant, and the third option being an off-the-shelf implant;

sending a request for manufacturing the selected implant to a manufacturing center;

receiving the implant; and

forward the implant for implantation.

2. The method of claim 1, further comprising receiving an alignment guide design recommendation from the surgeon.

3. The method of claim 2, further comprising providing the alignment guide and implant to the surgeon in one package.

4. The method of claim 3, further comprising including a disposable instrument in the package.

5. The method of claim 3, wherein the semi-custom made implant is customizable to the patient from a generic casting of a specific implant component.

6. The method of claim 5, further comprising:

selecting the semi-custom implant; and

machining at least one geometric feature of the generic casting for a size specific to the patient.

7. The method of claim 6, further comprising machining at least one feature of the generic casting to a shape specific for the patient.

8. The method of claim 6, further comprising machining a height of the implant specific the patient.

9. The method of claim 6, further comprising machining a width of the implant specific the patient.

10. The method of claim 6, further comprising casting cement well in an internal surface of the implant.

11. An orthopedic implant manufacturing method comprising:

providing a generic casting of a specific implant component, the generic casting having at least one geometric feature that can be machined to a plurality of different sizes of the implant component, the generic casting including size-independent features of the specific component; and

machining the component to a patient-specified size.

12. The method of claim 11, wherein machining the component to a patient-specified size comprises machining to a specific width and height.

13. The method of claim 11, wherein the implant component is a femoral component and the method further comprises machining a patient-specific patella track.

14. The method of claim 11, wherein the size-independent features in the generic casting include cement wells.

15. The method of claim 11, wherein the generic casting includes at least one geometric feature characteristic of the implant component, the geometric feature machinable to a plurality of different shapes.

16. The method of claim 11, wherein the generic casting can be machined to a right or left implant component.

17. A device comprising a generic casting for a specific implant component, the generic casting being intermediate between stock material and a specific size implant component, the generic casting including at least one size-independent feature of the implant component, and at least one feature machinable to size/shape for a specific patient.

18. The device of claim 17, wherein the at least size-independent feature includes a cement well.

19. The device of claim 17, wherein the at least feature machinable to size/shape includes a medial-lateral width of the implant component.

20. The device of claim 17, wherein the at least features machinable to size/shape includes a height of the implant component.

21. The device of claim 17, wherein the at least features machinable to size/shape includes a bone-engagement surface of the implant component.

22. The device of claim 17, wherein the at least feature machinable to shape includes an intercondylar notch area of the implant component.

23. The device of claim 17, wherein the at least feature machinable to size/shape includes a patella track of the implant component.