PATIENT-SPECIFIC MILL GUIDE

• US 20110106093A1
• Filed: 10/19/2010
• Published: 05/05/2011
• Est. Priority Date: 10/29/2009
• Status: Active Grant

• Current Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Romano, Anthony P., May, Justin J.
• Granted Patent: US 9,839,434 B2
• Time in Patent Office: Days
• US Class Current: 606/88
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/1675 for the knee
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2017/1602 Mills
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2090/034 abutting on parts of the device itself
• 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 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/3895 unicompartimental
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• CPC Class Codes: A61F 2240/002 Designing or making customized prostheses

Abstract

A patient-specific surgical system, such as a patient-specific milling guide, is provided for preparing a bone to receive an orthopedic prosthesis.

Claims

1. An orthopedic guide for preparing a particular patient'"'"'s bone to receive a prosthesis using a milling tool with a rotating burr, the orthopedic guide comprising:

a platform having a top surface and a bottom surface that faces the patient'"'"'s bone, the platform defining an elongate milling track that extends through the platform from the top surface to the bottom surface of the platform, the milling track being sized and shaped to guide the milling tool across the patient'"'"'s bone with the burr of the milling tool rotating beneath the bottom surface of the platform to remove a first bone portion from the patient'"'"'s bone; and

a plurality of legs coupled to the platform, each of the plurality of legs comprising a referencing end that is contoured to abut the patient'"'"'s bone, the referencing ends of the plurality of legs cooperating to locate the orthopedic guide at a predetermined location of the patient'"'"'s bone.

2. The orthopedic guide of claim 1, wherein the plurality of legs project beneath the bottom surface of the platform such that the bottom surface of the platform hovers above the patient'"'"'s bone when the referencing ends of the plurality of legs abut the patient'"'"'s bone.

3. The orthopedic guide of claim 1, wherein the plurality of legs are spaced apart about a periphery of the platform.

4. The orthopedic guide of claim 1, wherein the platform includes an anterior portion, an intermediate portion that extends obtusely from the anterior portion of the platform, and a distal portion that extends obtusely from the intermediate portion of the platform, the orthopedic guide configured for use with the patient'"'"'s femur such that the anterior portion of the platform rests above an anterior surface of the patient'"'"'s femur and the distal portion of the platform rests above a distal surface of the patient'"'"'s femur.

5. The orthopedic guide of claim 4, wherein the milling track spans the anterior portion, the intermediate portion, and the distal portion of the platform.

6. The orthopedic guide of claim 1, wherein the platform includes an anterior portion and a distal portion that extends substantially perpendicular to the anterior portion of the platform, the orthopedic guide configured for use with the patient'"'"'s femur such that the anterior portion of the platform rests above an anterior surface of the patient'"'"'s femur and the distal portion of the platform rests above a distal surface of the patient'"'"'s femur.

7. The orthopedic guide of claim 1, wherein the milling track includes an enlarged opening for receiving the burr of the milling tool, the milling track narrowing in width apart from the enlarged opening to retain the burr of the milling tool beneath the platform.

8. The orthopedic guide of claim 1, wherein the milling track includes a plurality of substantially parallel segments and a transverse interconnecting segment that joins together the plurality of substantially parallel segments.

9. The orthopedic guide of claim 1, wherein the platform further defines a substantially planar cut referencing surface that is configured to guide a cutting tool across the patient'"'"'s bone to remove a second bone portion from the patient'"'"'s bone.

10. The orthopedic guide of claim 9, wherein the cut referencing surface is located on an exterior surface of the platform.

11. A method for preparing a particular patient'"'"'s bone to receive a prosthesis having an articulating surface and a bone-engaging surface, the method comprising the steps of:

providing a digital model of the bone;

identifying a portion of the bone to be removed to receive the prosthesis;

providing a patient-specific guide;

using the patient-specific guide to remove the identified portion of the bone, thereby forming a prepared surface of the bone; and

inlaying the prosthesis into the bone by positioning the bone-engaging surface of the prosthesis against the prepared surface of the bone, the articulating surface of the prosthesis transitioning smoothly into a remaining surface of the bone located adjacent to the prepared surface of the bone.

12. The method of claim 11, further comprising the step of providing a digital model of the prosthesis.

13. The method of claim 12, wherein the identifying step comprises overlaying the digital model of the prosthesis onto the digital model of the bone.

14. The method of claim 11, wherein the using step comprises at least one of milling and cutting the bone.

15. The method of claim 11, wherein the inlaying step comprises aligning the articulating surface of the prosthesis and the remaining surface of the bone in substantially the same plane.

16. A method for preparing a particular patient'"'"'s bone to receive a prosthesis, the method comprising the steps of:

providing a digital model of the bone;

providing a digital model of the prosthesis, the digital model of the prosthesis having a bone-contacting surface with a predetermined shape;

identifying a portion of the bone to be removed to receive the bone-contacting surface of the prosthesis;

providing a patient-specific guide to remove the identified portion of the bone; and

manufacturing the prosthesis to fill at least the removed portion of the bone.

17. The method of claim 16, wherein the removed portion of the bone has a three-dimensional geometry, the manufacturing step comprising manufacturing the prosthesis to replicate the three-dimensional geometry of the removed portion of the bone.

18. The method of claim 16, wherein the manufacturing step comprises at least one of a rapid prototyping process and a casting process.

19. The method of claim 16, wherein the manufacturing step comprises removing material from a bulk construct to form an articulating surface of the prosthesis while retaining a bone-engaging surface of the bulk construct.

20. The method of claim 16, wherein the patient-specific guide is contoured to rest against a predetermined location of the bone.