SYSTEM AND METHOD FOR MANUFACTURING ARTHROPLASTY JIGS

• US 20090157083A1
• Filed: 12/18/2007
• Published: 06/18/2009
• Est. Priority Date: 12/18/2007
• Status: Active Grant

• Current Assignee: Howmedica Osteonics Corp. (Stryker Corporation)
• Original Assignee: Otismed Corporation (Stryker Corporation)
• Inventors: Park, Ilwhan, Howell, Stephen M.
• Granted Patent: US 8,221,430 B2
• Time in Patent Office: Days
• US Class Current: 606/88
• CPC Class Codes: A61B 17/15 Guides therefor arrangements for guiding straight saw blades in general B23D51/025
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1703 using imaging means, e.g. by X-rays
• CPC Class Codes: A61B 17/1725 for applying transverse screws or pins through intramedullary nails or pins
• CPC Class Codes: A61B 17/1739 specially adapted for particular parts of the body
• CPC Class Codes: A61B 17/1742 for the hip
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 17/58 for osteosynthesis, e.g. bone plates, screws , setting implements or the like A61B17/14, A61B17/16 take precedence
• CPC Class Codes: A61B 2034/105 Modelling of the patient, e.g. for ligaments or bones
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61B 5/055 involving electronic [EMR] or nuclear [NMR] magnetic resonance, e.g. magnetic resonance imaging
• CPC Class Codes: A61B 5/4514 Cartilage
• CPC Class Codes: A61B 5/4528 Joints A61B5/4533, A61B5/4538 take precedence
• CPC Class Codes: A61B 6/03 Computed tomography [CT] echo-tomography A61B8/14

Abstract

Disclosed herein is a method of computer generating a three-dimensional surface model of an arthroplasty target region of a bone forming a joint. The method may include: generating two-dimensional images of at least a portion of the bone; generating an open-loop contour line along the arthroplasty target region in at least some of the two-dimensional images; and generating the three-dimensional model of the arthroplasty target region from the open-loop contour lines.

Claims

1. A method of manufacturing an arthroplasty jig, the method comprising:

generating two-dimensional images of at least a portion of a bone forming a joint;

generating a first three-dimensional computer model of the at least a portion of the bone from the two-dimensional images;

generating a second three-dimensional computer model of the at least a portion of the bone from the two-dimensional images;

causing the first and second three-dimensional computer models to have in common a reference position, wherein the reference position includes at least one of a location and an orientation relative to an origin;

generating a first type of data with the first three-dimensional computer model;

generating a second type of data with the second three-dimensional computer model;

employing the reference position to integrate the first and second types of data into an integrated jig data; and

using the integrated jig data at a manufacturing machine to manufacture the arthroplasty jig.

2. The method of claim 1, wherein the first three-dimensional computer model is a bone only model and the second three-dimensional computer model is a bone and cartilage model.

3. The method of claim 2, wherein the bone only and bone and cartilage models represent a degenerated state of the joint.

4. The method of claim 1, wherein the first three-dimensional computer model represents an approximation of the at least a portion of the bone in a pre-degenerated state and the second three-dimensional computer model represents the at least a portion of the bone with cartilage in a degenerated state.

5. The method of claim 1, wherein the first type of data includes at least one of saw cut and drill hole information, and the second type of data includes surface contour information of the at least a portion of the bone.

6. The method of claim 5, wherein the saw cut and drill hole information includes at least one of location, orientation and size of at least one of a proposed arthroplasty saw cut and drill hole.

7. The method of claim 1, wherein the second three-dimensional computer model is generated at least in part from open-loop contour lines derived at least in part from the two-dimensional images.

8. The method of claim 1, wherein the second three-dimensional computer model is generated at least in part from closed-loop contour lines derived at least in part from the two-dimensional images.

9. The method of claim 1, wherein the first three-dimensional computer model is a three-dimensional volumetric model.

10. The method of claim 1, wherein the second three-dimensional computer model is a three-dimensional surface model.

11. The method of claim 1, wherein the two-dimensional images are MRI images.

12. The method of claim 1, wherein the two-dimensional images are CT images.

13. The method of claim 1, wherein the reference position is at least one of a point, multiple points, a vector, a plane, and a plane plus a point.

14. The method of claim 1, wherein the reference position is near the joint in the two-dimensional images.

15. The method of claim 1, wherein the joint is at least one of a knee, elbow, wrist, ankle, shoulder, hip and vertebrae interface.

16. The method of claim 1, wherein a change in location or orientation relative to the origin for one of the three-dimensional models causes an equal change in location or orientation relative to the origin for the other of the three-dimensional models.

17. The method of claim 1, further comprising:

comparing dimensions of the at least a portion of the bone to candidate jig blanks;

selecting from the candidate jig blanks a jig blank with the smallest dimensions that are able to accommodate the dimensions of the at least a portion of the bone; and

providing the selected jig blank to the manufacturing machine.

18. The method of claim 17, further comprising:

mathematically modifying the dimensions of the at least a portion of the bone and using the mathematically modified dimensions in determining which candidate jig blank to select.

19. The method of claim 17, where the dimensions of the at least a portion of the bone are obtained from at least one of the two-dimensional images and the three-dimensional images.

20. An arthroplasty jig manufactured according to claim 1.

21. A method of manufacturing an arthroplasty jig, the method comprising:

generating two-dimensional images of at least a portion of a bone forming a joint;

extending an open-loop contour line along an arthroplasty target region in at least some of the two-dimensional images;

generating a three-dimensional computer model of the arthroplasty target region from the open-loop contour lines;

generating from the three-dimensional computer model surface contour data pertaining to the arthroplasty target area; and

using the surface contour data at a manufacturing machine to manufacture the arthroplasty jig.

22. The method of claim 21, wherein the three-dimensional computer model is a bone and cartilage model.

23. The method of claim 22, wherein the bone and cartilage model represents a degenerated state of the joint.

24. The method of claim 21, wherein the three-dimensional computer model is a three-dimensional surface model.

25. The method of claim 21, wherein the two-dimensional images are MRI images.

26. The method of claim 21, wherein the two-dimensional images are CT images.

27. The method of claim 21, wherein the joint is at least one of a knee, elbow, wrist, ankle, shoulder, hip and vertebrae interface.

28. The method of claim 21, further comprising:

comparing dimensions of the at least a portion of the bone to candidate jig blanks;

selecting from the candidate jig blanks a jig blank with the smallest dimensions that are able to accommodate the dimensions of the at least a portion of the bone; and

providing the selected jig blank to the manufacturing machine.

29. The method of claim 28, further comprising:

mathematically modifying the dimensions of the at least a portion of the bone and using the mathematically modified dimensions in determining which candidate jig blank to select.

30. The method of claim 29, where the dimensions of the at least a portion of the bone are obtained from at least one of the two-dimensional images and the three-dimensional images.

31. The method of claim 21, wherein the open-loop contour lines extend immediately adjacent cortical bone and cartilage of the arthroplasty target region.

32. An arthroplasty jig manufactured according to claim 21.

33. A method of computer generating a three-dimensional surface model of an arthroplasty target region of a bone forming a joint, the method comprising:

generating two-dimensional images of at least a portion of the bone;

generating an open-loop contour line along the arthroplasty target region in at least some of the two-dimensional images; and

generating the three-dimensional model of the arthroplasty target region from the open-loop contour lines.

34. The method of claim 33, wherein the three-dimensional model is a bone and cartilage model.

35. The method of claim 34, wherein the bone and cartilage model represents a degenerated state of the joint.

36. The method of claim 33, wherein the two-dimensional images are MRI images.

37. The method of claim 33, wherein the two-dimensional images are CT images.

38. The method of claim 33, wherein the joint is at least one of a knee, elbow, wrist, ankle, shoulder, hip and vertebrae interface.

39. The method of claim 33, wherein the open-loop contour lines extend immediately adjacent cortical bone and cartilage of the arthroplasty target region.

40. A method of manufacturing an arthroplasty jig, the method comprising:

determining from an image at least one dimension associated with a portion of a bone;

comparing the at least one dimension to dimensions of at least two candidate jig blank sizes;

selecting the smallest of the jig blank sizes that is sufficiently large to accommodate the at least one dimension;

providing a jig blank of the selected size to a manufacturing machine; and

manufacturing the arthroplasty jig from the jig blank.

41. The method of claim 40, wherein the image is a two-dimensional MRI image.

42. The method of claim 40, wherein the image is a two-dimensional CT image.

43. The method of claim 40, wherein the image is a three-dimensional computer generated surface model.

44. The method of claim 40, wherein the image is a three-dimensional computer generated volume model.

45. The method of claim 40, wherein the at least one dimension is an anterior-posterior extent of a femur arthroplasty target region.

46. The method of claim 40, wherein the at least one dimension is an medial-lateral extent of a femur arthroplasty target region.

47. The method of claim 40, wherein the at least one dimension is an medial-lateral extent of a tibia arthroplasty target region.

48. The method of claim 40, wherein the processes of (1) determining from an image at least one dimension associated with a portion of a bone and (2) comparing the at least one dimension to dimensions of at least two candidate jig blank sizes further comprise mathematically modifying the at least one dimension and using the mathematically modified dimensions for the comparison.

49. An arthroplasty jig manufactured according to claim 40.

50. A method of generating a three-dimensional arthroplasty jig computer model, the method comprising:

comparing a dimension of at least a portion of a bone of a joint to candidate jig blank sizes; and

selecting from the candidate jig blank sizes a smallest jig blank size able to accommodate the dimensions of the at least a portion of the bone.

51. The method of claim 50, further comprising forming an exterior three-dimensional surface model from an exterior surface of a model of the smallest jig blank size.

52. The method of claim 51, further comprising:

forming an interior three-dimensional surface model from an arthroplasty target region of the at least a portion of the bone; and

combining the exterior surface model and interior surface model to respectively form the exterior surface and interior surface of the three-dimensional arthroplasty jig computer model.

53. A method of generating a three-dimensional arthroplasty jig computer model, the method comprising:

forming an interior three-dimensional surface model representing an arthroplasty target region of at least a portion of a bone;

forming an exterior three-dimensional surface model representing an exterior surface of a jig blank; and

combining the interior surface model and exterior surface model to respectively form the interior surface and exterior surface of the three-dimensional arthroplasty jig computer model.

54. The method of claim 53, wherein the interior surface model and exterior surface models are spaced apart each other when combined.

55. The method of claim 54, further comprising joining the interior surface model to the exterior surface model.

56. The method of claim 55, wherein the joining process results in a three-dimensional volume model for the three-dimensional arthroplasty jig computer model.

57. A method of generating a production file associated with the manufacture of arthroplasty jigs, the method comprising:

generating first data associated a surface contour of an arthroplasty target region of a joint bone;

generating second data associated with at least one of a saw cut and a drill hole to be administered to the arthroplasty target region during an arthroplasty procedure; and

integrating first and second data,

wherein a positional relationship of first data relative to an origin and a positional relationship of second data relative to the origin are coordinated with each other to be generally identical during the respective generations of first and second data.

58. The method of claim 57, wherein the positional relationships include at least one of location and orientation relative to the origin.

59. The method of claim 57, further comprising:

generating two-dimensional images of the bone;

computer generating a three-dimensional model of the bone from the two-dimensional images; and

establishing the positional relationships of first and second data relative to the origin from a relationship of at least one of the two-dimensional images and three-dimensional model relative to the origin.

60. The method of claim 57, wherein the joint bone is part of a knee, elbow, hip, shoulder, wrist, ankle or vertebrae interface.