Patient-Specific Implants With Improved Osseointegration

• US 20110008754A1
• Filed: 07/10/2009
• Published: 01/13/2011
• Est. Priority Date: 07/10/2009
• Status: Active Grant

• Current Assignee: Zimmer Dental Inc. (Zimvie Incorporated)
• Original Assignee: Zimmer Dental Inc. (Zimvie Incorporated)
• Inventors: Bassett, Jeffrey A., Collins, Michael, Cahill, Sean
• Granted Patent: US 9,707,058 B2
• Time in Patent Office: Days
• US Class Current: 433/175
• CPC Class Codes: A61C 8/0012 characterised by the material or composition, e.g. ceramics, surface layer, metal alloy use of specific materials A61K6/00
• CPC Class Codes: A61C 8/0013 with a surface layer, coating
• CPC Class Codes: A61F 2/2803 for mandibular reconstruction temporo-mandibular joints A61F2/3099; bone plates for the jaw A61B17/8071
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• 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 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30929 having at least two superposed coatings
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: A61F 2250/0023 differing in porosity
• CPC Class Codes: A61F 2310/00161 Carbon; Graphite
• CPC Class Codes: A61F 2310/00544 Coating made of tantalum or Ta-based alloys
• CPC Class Codes: A61L 2430/02 for reconstruction of bones; weight-bearing implants
• CPC Class Codes: A61L 27/08 Carbon ; Graphite
• CPC Class Codes: A61L 27/30 Inorganic materials
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49568 Orthodontic device making

Abstract

A patient-specific bone implant has a porous body with a core material covered with tantalum. It is made with unique outer dimensions selected to match a specific patient.

Claims

1. A patient-specific bone implant, comprising:

a porous body for being place on bone and having a core material covered with tantalum and made with unique outer dimensions selected to match a specific patient.

2. The implant of claim 1 wherein the implant is a root-form implant that corresponds to the root of a single tooth and supports at least one prosthesis.

3. The implant of claim 1 wherein the implant supports more than one prosthesis.

4. The implant of claim 1 wherein the implant is a plate-form implant having a generally flat plate portion for engaging the mandible or maxillae and made of the porous material, and at least one post extending coronally from the plate portion to support at least one prosthesis on each post.

5. The implant of claim 4 wherein the at least one post is made of a non-porous material secured to the plate portion.

6. The implant of claim 1 wherein the implant replaces multiple tooth root sockets.

7. The implant of claim 1 wherein the implant extends apically of the alveolar margin.

8. The implant of claim 1 wherein the implant forms a region of the mandible or maxillae that is other than directly apical of a posterior tooth.

9. The implant of claim 1 comprising a plurality of posts extending coronally from the porous body, wherein each post supports at least one prosthetic tooth.

10. The implant of claim 9 wherein at least one of the posts is made of a porous metal.

11. The implant of claim 1 wherein the porous body comprises at least one cavity for receiving at least one post to support at least one prosthetic tooth.

12. The implant of claim 11 wherein the at least one post is made of a porous metal.

13. The implant of claim 11 further comprising a non-porous anchor member extending within the cavity and engaging the post in the cavity to secure the post in the cavity.

14. The implant of claim 13 further comprising a plurality of porous bodies, each porous body having at least one of the anchor members arranged so that a single post secures multiple porous bodies to each other.

15. The implant of claim 13 wherein the porous body further comprises an outer surface and a hole extending from the outer surface and opening at the cavity, the anchor member extending through the hole into the cavity.

16. The implant of claim 13 wherein the post and anchor member engage in a threaded connection.

17. A bone implant comprising:

a block of porous material having a core material covered with tantalum, the block having pre-set outer dimensions selected from a group of blocks each with different pre-set outer dimensions corresponding to a predetermined location on a mandible or maxilla, the block being configured to selectively alternatively support and not support a prosthetic tooth.

18. The implant of claim 17 wherein a plurality of the blocks each have at least one cavity for receiving at least one post to support at least one prosthetic tooth.

19. The implant of claim 18 wherein the at least one post is made of a porous metal.

20. The implant of claim 18 further comprising a non-porous anchor member extending within the cavity and engaging the post in the cavity to secure the post in the cavity.

21. The implant of claim 20 wherein the anchor members are arranged within the blocks so that a single post secures multiple blocks to each other.

22. The implant of claim 18 wherein the post is configured to support at least one prosthetic tooth.

23. A method of forming a bone implant, comprising:

providing a block of porous material having a coating of metal; and

shaping the block to have dimensions matching dimensions of bone on a specific patient.

24. The method of claim 23 wherein the metal is tantalum.

25. The method of claim 23 further comprising securing at least one non-porous portion to the block to support at least one prosthetic tooth.

26. The method of claim 23 wherein shaping includes dimensioning the block to correspond to the size of a cavity on the bone of the specific patient.

27. The method of claim 23 wherein shaping includes dimensioning the block to correspond to the lateral curvature of the mandible or maxillae.

28. The method of claim 23 wherein the block is shaped to extend apically of the alveolar margin.

29. The method of claim 23 further comprising designing a prosthesis to be supported by the block on the same 3D model used to design the block.

30. The method of claim 23 wherein the porous material is shaped before the coating is placed on the porous material.

31. The method of claim 23 wherein the porous material is shaped after a first of a plurality of the coatings are placed on the porous material.