Patient-Specific Orthopedic Instruments

• US 20110071533A1
• Filed: 11/29/2010
• Published: 03/24/2011
• Est. Priority Date: 02/27/2006
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Catanzarite, Joshua B., May, Brian M., Metzger, Robert
• Granted Patent: US 8,591,516 B2
• Time in Patent Office: Days
• US Class Current: 606/88
• 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 17/58 for osteosynthesis, e.g. bone plates, screws , setting implements or the like A61B17/14, A61B17/16 take precedence
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• 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: 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 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/30014 differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2002/30062 (bio)absorbable, biodegradable, bioerodable, (bio)resorbable, resorptive
• CPC Class Codes: A61F 2002/30561 breakable or frangible
• CPC Class Codes: A61F 2002/30604 modular
• CPC Class Codes: A61F 2002/30617 Visible markings for adjusting, locating or measuring
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/4662 for measuring penetration depth
• CPC Class Codes: A61F 2002/4668 for measuring angles
• CPC Class Codes: A61F 2002/4677 using a guide wire

Abstract

An orthopedic device includes a patient-specific alignment guide operable for preparing a bone of a patient for resection during joint arthroplasty. The alignment guide includes a patient-specific bone engagement surface complementary to a surface of the bone of the patient and imaged from a bone scan of the patient. The alignment guide includes a plurality of guiding bores, and a plurality of alignment pins received through corresponding guiding bores for attaching the alignment guide to the bone. The alignment pins are resorbable and can be cut off during a resection of the bone.

Claims

1. An orthopedic device comprising:

a patient-specific alignment guide operable for preparing a bone of a patient for resection during joint arthroplasty, the alignment guide including a patient-specific bone engagement surface complementary to a surface of the bone of the patient, the surface of the bone imaged from a bone scan of the patient, the alignment guide including a plurality of guiding bores; and

a plurality of alignment pins receivable through corresponding guiding bores for attaching the alignment guide to the bone, wherein the alignment pins are resorbable and configured to be cut off during a resection of the bone.

2. The orthopedic device of claim 1, wherein the alignment pins are cannulated.

3. The orthopedic device of claim 2, further comprising a cutting block including a plurality of pins configured to be receivable into corresponding cut-off alignment pins for another resection of the bone.

4. The orthopedic device of claim 1, wherein the alignment guide is configured to be cut off during a resection of the bone.

5. The orthopedic device of claim 1, wherein the alignment guide is a femoral alignment guide for a distal femur and is configured to be cut off during a distal resection in which a pair of distal pins from the plurality of alignment pins are also cut off.

6. The orthopedic device of claim 5, further comprising a distal cutting block mounted on a pair of anterior alignment pins from the plurality of alignment pins.

7. The orthopedic device of claim 1, wherein the alignment guide is a femoral alignment guide for a distal femur and is configured to be cut off during a distal resection without cutting off a pair of distal pins from the plurality of alignment pins.

8. The orthopedic device of claim 7, wherein the plurality of guiding bores includes a pair of distal guiding bores oriented at an oblique angle relative to the surface of the femur and receiving the pair of distal pins.

9. The orthopedic device of claim 1, wherein the alignment guide is a tibial alignment guide including a proximal portion engageable with a proximal surface of the tibia, an anterior portion engageable with an anterior surface of the tibia and an elongated slot in the anterior portion for guiding a tibial resection according to a pre-operative plan for the patient.

10. The orthopedic device of claim 9, wherein the proximal portion of the tibial alignment guide defines an opening for receiving a tool.

11. The orthopedic device of claim 10, wherein the opening is shaped for receiving a finned stem punch in a direction aligned to an intramedullary canal of the tibia in preparation for a tibial stem implant.

12. The orthopedic device of claim 10, further comprising a metal insert removably received in the opening.

13. The orthopedic device of claim 12, wherein the metal insert is shaped for receiving a finned stem punch.

14. The orthopedic device of claim 9, further comprising a guide tool having a proximal portion including a pair of apertures shaped to be positioned over corresponding proximal guiding bores of the alignment guide and an anterior portion having an elongated slot shaped to be positioned over the elongated slot of the tibial alignment guide.

15. The orthopedic device of claim 9, further comprising a guide tool having an anterior portion having an elongated slot and a proximal portion including a pair of apertures shaped to be positioned over a pair corresponding proximal alignment pins from the plurality of the alignment pins after the tibial alignment guide is removed.

16. An orthopedic device comprising:

a patient-specific tibial alignment guide operable for preparing a tibia of a patient for resection during joint arthroplasty, the tibial alignment guide including;

a first portion engageable with a proximal surface of the tibia, the first portion defining first and second proximal guiding bores and an opening between the first and second proximal guiding bores;

a second portion engageable with an anterior surface of the tibia, the second portion defining first and second anterior guiding bores and an elongated slot for guiding a blade for resecting of the tibia;

a patient-specific bone engagement surface defined by the first and second portions and complementary to the proximal and anterior surface of the tibia; and

a plurality of alignment pins receivable through respective proximal and anterior guiding bores for attaching the alignment guide to the tibia, wherein the alignment pins are resorbable and can be cut off during resection of the tibia.

17. The orthopedic device of claim 16, wherein the opening of the first portion defines a plurality of fin-shaped slots for receiving a finned stem punch.

18. The orthopedic device of claim 16, further comprising a removable metal insert shaped to be mateably and removably received in the opening of the first portion.

19. The orthopedic device of claim 18, wherein the metal insert defines a plurality of fin-shaped slots for receiving a finned stem punch.

20. The orthopedic device of claim 18, further comprising a modular handle removably coupled to the metal insert.

21. A method of preparing a distal femur for a knee joint implant, the method comprising:

mounting a patient-specific bone engagement surface of a femoral alignment guide on a complementary surface of a distal femur of a patient;

inserting first and second anterior alignment pins into an anterior surface of the distal femur through corresponding first and second anterior guiding bores of the femoral alignment guide, wherein the first and second anterior alignment pins are resorbable;

inserting first and second distal alignment pins into a distal surface of the distal femur through corresponding first and second distal guiding bores of the femoral alignment guide, wherein the first and second distal alignment pins are resorbable;

supporting a distal cutting guide on the first and second anterior alignment pins;

passing a cutting blade through a cutting slot of the cutting guide; and

resecting the distal femur with the cutting blade by cutting through the alignment guide and the first and second distal alignment pins to form a resected distal surface.

22. The method of claim 21, further comprising:

removing the distal cutting guide and the femoral alignment guide;

inserting first and second pins of a cutting block through cannulated bores of the cut-off first and second distal alignment pins;

mounting the cutting block on the resected distal surface; and

resecting the anterior surface of the distal femur while cutting through the first and second anterior alignment pins.

23. The method of claim 21, further comprising leaving portions of the first and second distal alignment into the distal femur to be resorbed.