Customized Patient-Specific Multi-Cutting Blocks

• US 20090088754A1
• Filed: 09/29/2008
• Published: 04/02/2009
• Est. Priority Date: 09/30/2007
• Status: Active Grant

• Current Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Original Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Inventors: Wyss, Joseph G., Sokolov, Dimitri, Aker, Chris
• Granted Patent: US 8,425,524 B2
• Time in Patent Office: Days
• US Class Current: 606/79
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: Y10T 409/30084 with regulation of operation by templet, card, or other replaceable information supply

Abstract

A number of orthopaedic surgical instruments are also disclosed. A method, apparatus, and system for fabricating such instruments are also disclosed.

Claims

1. A customized patient-specific orthopaedic instrument, comprising:

a cutting block having (i) an anterior bone-facing surface configured to receive a portion of an anterior side of a bone of a patient, and (ii) a distal bone-facing surface configured to receive a portion of a distal side of the bone of the patient,

wherein the anterior bone-facing surface has (i) a first flat surface that extends distally in a direction away from the proximal-most edge of the bone cutting block and toward the distal bone-facing surface of the cutting block, (ii) an anterior customized patient-specific negative contour surface that extends distally away from the first flat surface, the anterior customized patient-specific negative contour surface being configured to receive the portion of the anterior side of the bone of the patient that has a corresponding contour, and (iii) a second flat surface that extends distally from the anterior customized patient-specific negative contour surface toward the distal bone-facing surface, and

wherein the distal bone-facing surface has (i) a first flat surface that extends posteriorly in a direction away from the anterior bone-facing surface of the bone cutting block and toward the posterior-most edge of the cutting block, (ii) a distal customized patient-specific negative contour surface that extends posteriorly away from the first flat surface, the distal customized patient-specific negative contour surface being configured to receive the portion of the distal side of the bone of the patient that has a corresponding contour, and (iii) a second flat surface that extends posteriorly from the distal customized patient-specific negative contour surface toward the posterior-most edge of the cutting block.

2. The customized patient-specific orthopaedic instrument of claim 1, wherein:

the cutting block is generally L-shaped having (i) an anterior plate, and (ii) a distal plate secured to, and extending away from, the anterior plate,

the anterior bone-facing surface is defined in the anterior plate, and

the distal bone-facing surface is defined in the distal plate.

3. The customized patient-specific orthopaedic instrument of claim 2, wherein the anterior plate has a distal cutting guide extending therethrough.

4. The customized patient-specific orthopaedic instrument of claim 3, wherein the distal plate has both (i) an anterior cutting guide, and (ii) a posterior cutting guide extending therethrough.

5. The customized patient-specific orthopaedic instrument of claim 4, wherein the distal plate further has a pair of angled cutting guides extending therethrough.

6. The customized patient-specific orthopaedic instrument of claim 2, wherein the distal plate has an anterior cutting guide extending therethrough.

7. The customized patient-specific orthopaedic instrument of claim 2, wherein the distal plate has a posterior cutting guide extending therethrough.

8. The customized patient-specific orthopaedic instrument of claim 1, wherein:

the first flat surface of the anterior bone-facing surface transitions to the anterior customized patient-specific negative contour surface, and

the anterior customized patient-specific negative contour surface transitions to the second flat surface of the anterior bone-facing surface.

9. The customized patient-specific orthopaedic instrument of claim 1, wherein:

the first flat surface of the distal bone-facing surface transitions to the distal customized patient-specific negative contour surface, and

the distal customized patient-specific negative contour surface transitions to the second flat surface of the distal bone-facing surface.

10. A method of performing an orthopaedic surgical procedure on a bone of a patient, comprising:

securing a customized patient-specific cutting block to the bone of the patient such that (i) an anterior side of the bone of the patient is received into an anterior customized patient-specific negative contour surface of the cutting block, and (ii) a distal side of the bone of the patient is received into a distal customized patient-specific negative contour surface of the cutting block,

making an anterior cut in the bone of the patient with the cutting block such that a flat surface is formed on the anterior side of the bone of the patient,

making a distal cut in the bone of the patient with the cutting block such that a flat surface is formed on the distal side of the bone of the patient,

determining an amount of additional bone to be removed from the bone of the patient subsequent to making the anterior cut and the distal cut in the bone of the patient,

securing the customized patient-specific cutting block to the bone of the patient such that (i) the flat surface formed in the anterior side of the bone of the patient is positioned against at least one flat surface formed in an anterior bone-facing surface the cutting block, and (ii) the flat surface formed in the distal side of the bone of the patient is positioned against at least one flat surface formed in a distal bone-facing surface the cutting block, and

making at least one of (i) an additional anterior cut in the bone of the patient with the cutting block such that additional bone is removed from the flat surface formed on the anterior side of the bone of the patient, and (ii) an additional distal cut in the bone of the patient with the cutting block such that additional bone is removed from the flat surface formed on the distal side of the bone of the patient.

11. The method of claim 10, wherein securing the customized patient-specific cutting block to the bone of the patient such that (i) the anterior side of the bone of the patient is received into the anterior customized patient-specific negative contour surface of the cutting block, and (ii) the distal side of the bone of the patient is received into the distal customized patient-specific negative contour surface of the cutting block comprises:

securing the customized patient-specific cutting block to a femur of the patient such that (i) an anterior side of the femur of the patient is received into the anterior customized patient-specific negative contour surface of the cutting block, and (ii) a distal side of the femur of the patient is received into the distal customized patient-specific negative contour surface of the cutting block.

12. The method of claim 10, wherein making at least one of (i) an additional anterior cut in the bone of the patient with the cutting block such that additional bone is removed from the flat surface formed on the anterior side of the bone of the patient, and (ii) an additional distal cut in the bone of the patient with the cutting block such that additional bone is removed from the flat surface formed on the distal side of the bone of the patient comprises:

making both (i) an additional anterior cut in the bone of the patient with the cutting block such that additional bone is removed from the flat surface formed on the anterior side of the bone of the patient, and (ii) an additional distal cut in the bone of the patient with the cutting block such that additional bone is removed from the flat surface formed on the distal side of the bone of the patient.

13. A customized patient-specific orthopaedic instrument, comprising:

a cutting block having (i) an anterior customized patient-specific negative contour surface that is configured to receive a portion of the anterior side of the bone of the patient that has a corresponding contour, and (ii) a distal customized patient-specific negative contour surface that is configured to receive a portion of the distal side of the bone of the patient that has a corresponding contour, and (iii) a posterior customized patient-specific negative contour surface that is configured to receive a portion of the posterior side of the bone of the patient that has a corresponding contour.

14. The customized patient-specific orthopaedic instrument of claim 13, wherein:

the cutting block is generally U-shaped having (i) an anterior plate, (ii) a distal plate, and (iii) a posterior plate,

the anterior bone-facing surface is defined in the anterior plate,

the distal bone-facing surface is defined in the distal plate, and

the posterior bone-facing surface is defined in the posterior plate.

15. The customized patient-specific orthopaedic instrument of claim 14, wherein the anterior plate has a distal cutting guide extending therethrough.

16. The customized patient-specific orthopaedic instrument of claim 15, wherein the distal plate has both (i) an anterior cutting guide, and (ii) a posterior cutting guide extending therethrough.

17. The customized patient-specific orthopaedic instrument of claim 16, wherein the distal plate further has a pair of angled cutting guides extending therethrough.

18. The customized patient-specific orthopaedic instrument of claim 14, wherein the distal plate has an anterior cutting guide extending therethrough.

19. The customized patient-specific orthopaedic instrument of claim 14, wherein the distal plate has a posterior cutting guide extending therethrough.