Surgical Tools Facilitating Increased Accuracy, Speed and Simplicity in Performing Joint Arthroplasty

• US 20100281678A1
• Filed: 05/10/2010
• Published: 11/11/2010
• Est. Priority Date: 05/25/2001
• Status: Active Grant

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Fitz, Wolfgang, Lang, Philipp, Steines, Daniel, Burdulis, Albert G. JR., Vargas-Voracek, Rene, Tsougarakis, Konstantinos
• Granted Patent: US 8,366,771 B2
• Time in Patent Office: Days
• US Class Current: 29/592
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/158 Cutting patella
• CPC Class Codes: A61B 17/1677 for the patella
• CPC Class Codes: A61B 17/1767 for the patella
• CPC Class Codes: A61B 2017/0023 disposable
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 5/4504 Bones A61B5/4547 takes precedence
• CPC Class Codes: A61B 5/4514 Cartilage
• CPC Class Codes: A61B 5/4528 Joints A61B5/4533, A61B5/4538 take precedence
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 29/49995 Shaping one-piece blank by removing material

Abstract

Disclosed herein are tools for repairing articular surfaces repair materials and for repairing an articular surface. The surgical tools are designed to be customizable or highly selectable by patient to increase the speed, accuracy and simplicity of performing total or partial arthroplasty.

Claims

1. A method of making a surgical tool, the method comprising:

obtaining image data associated with at least a portion of a joint;

deriving a substantially uncut cartilage surface associated with the joint from the image data;

deriving one of a mechanical axis and an anatomical axis associated with the joint from the image data; and

providing a surgical tool that includes a contact surface for engaging the substantially uncut cartilage surface associated with the joint, the surgical tool further including at least one guide for directing movement of a surgical instrument in preparing an implant site, wherein providing the surgical tool includes;

shaping the contact surface based on the derived cartilage surface such that the contact surface conforms to and is substantially a negative of the derived cartilage surface; and

determining position, shape and/or orientation of the at least one guide from the image data based, at least in part, on the one of a mechanical axis and the anatomical axis.

2. The method according to claim 1, further comprising:

positioning the at least one contact surface of the surgical tool onto the joint surface; and

directing movement of the surgical instrument using the at least one guide.

3. The method according to claim 2, wherein directing movement of the surgical instrument includes making at least one of a cut, a drill hole, and a reaming.

4. The method according to claim 1, further comprising adjusting the guide to the at least one position, shape and orientation.

5. The method according to claim 4, wherein the surgical tool includes a block that communicates with the at least one contact surface, the block including the guide, wherein adjusting the guide includes:

placing one of a spacer and a shim between the at least one contact surface and the block.

6. The method according to claim 4, wherein adjusting the guide includes using at least one of a ratchet mechanism, a hinge mechanism, and a jack mechanism.

7. The method according to claim 1, wherein obtaining an image includes obtaining an MRI image.

8. A method of making a surgical tool, the method comprising:

obtaining image data associated with at least a portion of a joint;

deriving a substantially uncut cartilage surface associated with the joint from the image data; and

providing a surgical tool that includes a contact surface for engaging the substantially uncut cartilage surface associated with the joint, the surgical tool further including at least one guide for directing movement of a surgical instrument in preparing an implant site, wherein providing the surgical tool includes;

machining the contact surface based on the derived cartilage surface such that the contact surface conforms to and is substantially a negative of the derived cartilage surface; and

determining position, shape and/or orientation of the at least one guide from the image data.

9. The method according to claim 8, further comprising:

positioning the at least one contact surface of the surgical tool onto the joint surface; and

directing movement of the surgical instrument using the at least one guide.

10. The method according to claim 9, wherein directing movement of the surgical instrument includes making at least one of a cut, a drill hole, and a reaming.

11. The method according to claim 8, further comprising adjusting the guide to the at least one position, shape and orientation.

12. The method according to claim 11, wherein the surgical tool includes a block that communicates with the at least one contact surface, the block including the guide, wherein adjusting the guide includes:

placing one of a spacer and a shim between the at least one contact surface and the block.

13. The method according to claim 11, wherein adjusting the guide includes using at least one of a ratchet mechanism, a hinge mechanism, and a jack mechanism.

14. The method according to claim 8, wherein obtaining an image includes obtaining an MRI image.

15. A method of making a surgical tool, the method comprising:

obtaining image data associated with at least a portion of a joint;

deriving a substantially uncut cartilage surface associated with the joint from the image data; and

providing a surgical tool that includes a contact surface for engaging the substantially uncut cartilage surface associated with the joint, the surgical tool further including at least one guide for directing movement of a surgical instrument in preparing an implant site, wherein providing the surgical tool includes;

molding the contact surface based on the derived cartilage surface such that the contact surface conforms to and is substantially a negative of the derived cartilage surface; and

determining position, shape and/or orientation of the at least one guide from the image data.

16. The method according to claim 15, further comprising:

positioning the at least one contact surface of the surgical tool onto the joint surface; and

directing movement of the surgical instrument using the at least one guide.

17. The method according to claim 16, wherein directing movement of the surgical instrument includes making at least one of a cut, a drill hole, and a reaming.

18. The method according to claim 15, further comprising adjusting the guide to the at least one position, shape and orientation.

19. The method according to claim 18, wherein the surgical tool includes a block that communicates with the at least one contact surface, the block including the guide, wherein adjusting the guide includes:

placing one of a spacer and a shim between the at least one contact surface and the block.

20. The method according to claim 18, wherein adjusting the guide includes using at least one of a ratchet mechanism, a hinge mechanism, and a jack mechanism.