Method And Apparatus For Manufacturing An Implant

• US 20090151736A1
• Filed: 02/13/2009
• Published: 06/18/2009
• Est. Priority Date: 04/17/2007
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Metzger, Robert, Belcher, Nathan Emick
• Granted Patent: US 9,907,659 B2
• Time in Patent Office: Days
• US Class Current: 128/898
• 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 2002/4633 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 pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient'"'"'s joint indicating at least one resection plane, communicating the surgical plan to a surgeon of the patient, and receiving approval of the surgical plan and the resection plane by the surgeon. The method also includes providing automated osteophyte/protrusion removal control for surgeon manipulation, receiving a modified three-dimensional image of a patient'"'"'s joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from the surgeon, and requesting manufacture of the selected orthopedic implant.

Claims

1. An orthopedic implant manufacturing method comprising:

preparing a pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient'"'"'s joint indicating at least one resection plane;

communicating the surgical plan to a surgeon of the patient;

receiving approval of the surgical plan and the resection plane by the surgeon;

providing automated osteophyte/protrusion removal control for surgeon manipulation;

receiving a modified three-dimensional image of a patient'"'"'s joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from the surgeon; and

requesting manufacture of the selected orthopedic implant.

2. The method of claim 1, wherein providing automated osteophyte/protrusion removal control for surgeon manipulation includes identifying a location of at least one osteophyte/protrusion on the three-dimensional image of a patient'"'"'s joint.

3. The method of claim 2, wherein providing automated osteophyte/protrusion removal control for surgeon manipulation includes providing a plurality of depth contours in relation to the osteophyte/protrusion.

4. The method of claim 3, wherein providing automated osteophyte/protrusion removal control for surgeon manipulation includes providing at least one graphical removal tool associated with the osteophyte/protrusion for manipulation by the surgeon.

5. The method of claim 3, wherein the plurality of depth contours is continuous.

6. The method of claim 5, further comprising referencing the plurality of depth contours from a landmark location associated with the osteophyte/protrusion.

7. The method of claim 2, wherein identifying a location of an osteophyte/protrusion on three-dimensional image of a patient'"'"'s joint includes determining a tissue overhang protruding from an edge of a resection plane.

8. The method of claim 1, further comprising receiving a recommendation for a selected alignment guide from the surgeon.

9. The method of claim 8, further comprising providing the selected alignment guide and selected orthopedic implant to the surgeon in one package.

10. The method of claim 1, wherein the selected orthopedic implant is a femoral joint component.

11. The method of claim 10, wherein the femoral joint component is custom made for a specific patient.

12. The method of claim 10, wherein the femoral joint component is semi-custom made.

13. The method of claim 1, wherein the selected orthopedic implant is a tibial joint component.

14. The method of claim 13, wherein the tibial joint component is custom made for a specific patient.

15. The method of claim 13, wherein the tibial joint component is semi-custom made.

16. An orthopedic implant manufacturing method comprising:

preparing a pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient'"'"'s joint indicating at least one resection plane;

communicating the surgical plan to a surgeon of the patient;

receiving approval of the surgical plan and the resection plane by the surgeon;

identifying a location of at least one osteophyte/protrusion on the three-dimensional image of a patient'"'"'s joint;

providing a plurality of depth contours in relation to the osteophyte/protrusion;

providing at least one graphical removal tool associated with the osteophyte/protrusion for manipulation by the surgeon;

receiving a modified three-dimensional image of a patient'"'"'s joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from the surgeon; and

requesting manufacture of the selected orthopedic implant.

17. The method of claim 16, wherein the plurality of depth contours is continuous.

18. The method of claim 17, further comprising referencing the plurality of depth contours from a landmark location associated with the osteophyte/protrusion.

19. The method of claim 17, wherein identifying a location of an osteophyte/protrusion on three-dimensional image of a patient'"'"'s joint includes determining a tissue overhang protruding from an edge of a resection plane.

20. The method of claim 17, further comprising receiving a recommendation for a selected alignment guide from the surgeon.

21. An orthopedic implant manufacturing method comprising:

preparing a pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient'"'"'s joint indicating at least one resection plane;

identifying a location of at least one osteophyte/protrusion on the three-dimensional image of a patient'"'"'s joint;

providing a plurality of depth contours in relation to the osteophyte/protrusion;

providing at least one graphical removal tool associated with the osteophyte/protrusion for manipulation by a user;

communicating the surgical plan to a user;

receiving a modified three-dimensional image of a patient'"'"'s joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from a user; and

requesting manufacture of the selected orthopedic implant.

22. The method of claim 21, further comprising:

receiving the selected orthopedic implant; and

forwarding the selected orthopedic implant for implantation.