Method of forming implantable prostheses for reconstructive surgery

• US 4,436,684 A
• Filed: 06/03/1982
• Issued: 03/13/1984
• Est. Priority Date: 06/03/1982
• Status: Expired due to Term

• Current Assignee: Biomet Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Contour Med Partners Limited
• Inventors: White, David N.
• Primary Examiner(s): Czaja, Donald E.
• Assistant Examiner(s): Housel, James C.
• Application Number:
  US06/384,646
• Time in Patent Office: 649 Days
• Field of Search: 434/82, 434/267, 434/270, 434/274, 378/4, 378/5, 378/6, 378/7, 378/8, 378/9, 378/10, 378/11, 378/12, 378/13, 378/14, 378/15, 378/16, 378/17, 378/18, 378/19, 378/20, 378/21, 128/303 B, 128/653, 264/138, 264/163, 264/219, 3/1.9, 28/92 C
• US Class Current: 264/138
• 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 2/2875 Skull or cranium A61F2/2803 and A61F2/3099 take precedence
• 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 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: B23Q 33/00 Methods for copying
• CPC Class Codes: G05B 19/4207 in which a model is traced or scanned and corresponding data recorded
• CPC Class Codes: G05B 2219/45168 Bone prosthesis
• CPC Class Codes: Y10S 623/901 Method of manufacturing prosthetic device
• CPC Class Codes: Y10S 623/914 Bone

Abstract

Non-invasive method of forming prostheses of skeletal structures internal to a body for use in reconstructive surgery. The selected internal skeletal structure is measured by subjecting the body to radiant energy to produce radiant energy responses that are detected to obtain representations delineating the skeletal structure. Three dimensional coordinate data defining the skeletal structure is generated from the obtained representations. The coordinate data is employed to control a sculpting tool to form the prosthesis.

Claims

1. A method of fabricating a three dimensional corporeal model of a structure internal to a body, comprising:

subjecting the body to radiant energy to produce radiant energy responses internal to said body, the radiant energy selected to produce radiant energy responses that are characteristic of a selected physical property of substances detectable exterior of the body;

detecting produced radiant energy responses to obtain representations of substances at locations internal to the body defining structures internal to said body three-dimensionally;

generating from the representations of the substances a set of three dimensional coordinates defining a three dimensional representation of a selected structure internal to the body; and

directing a sculpting tool into a workpiece in accordance with the generated set of three dimensional coordinates to form a corporeal model corresponding to the three dimensional representation of the selected structure.

2. The method of claim 1 wherein the subjecting step and detecting step are performed exterior to the body in which said selected structue is located.

3. The method of claim 1, further comprising:

displaying a visual representation of the selected structure defined by the set of three dimensional coordinates; and

selectively adjusting the three dimensional coordinates; and

wherein

the sculpting tool is directed into the workpiece in accordance with the adjusted three dimensional coordinates.

4. The method of claim 1 wherein:

the generated set of three dimensional coordinates defines an altered three dimensional representation of the selected structure; and

the formed corporeal model corresponds to the altered three dimensional representation of the selected structure.

5. The method of claim 4 wherein a set of transformed three dimensional coordinates are generated from the obtained representations of the substances to define the altered three dimensional representation of the selected structure, further comprising:

displaying a visual representation of the altered three dimensional representations of the selected structure defined by the set of transformed three dimensional coordinates; and

selectively adjusting the transformed three dimensional coordinates; and

wherein

the sculpting tool is directed into the workpiece in accordance with the transformed and selectively adjusted three dimensional coordinates.

6. The method of either claim 3, 4 or 5 wherein:

the generated set of three dimensional coordinates defines an ununiformly altered three dimensional representation of the selected structure; and

the directed sculpting tool forms a corporeal model corresponding to the ununiformly altered three dimensional representation of the selected structure.

7. The method of claim 6 wherein the generated set of three dimensional coordinates defines an altered three dimensional representation of the selected structure having a selected surface segment altered in a coordinate direction to effect a unidirectional translation of a corresponding selected surface segment in the formed corporeal model.

8. The method of either claim 3, 4 or 5 wherein:

the generated set of three dimensional coordinates defines a mirror image three dimensional representation of the selected structure; and

the directed sculpting tool forms a corporeal model corresponding to the mirror image three dimensional representation of the selected structure.

9. The method of claim 8 wherein:

the selected structure is a segment of a larger structure internal to the body having a nominal plane of general symmetry; and

the generated set of three dimensional coordinates defines a three dimensional representation of a mirror image of the selected structure taken relative to a mirror plane located at the nominal plane of general symmetry.

10. The method of claim 1 wherein the selected structure is a segment of a larger structure internal to the body having a nominal plane of general symmetry, and said segment is located at one side of said nominal plane of symmetry, further comprising:

transforming the three dimensinal coordinates generated from the obtained representations of substances to define a mirror image three dimensional representation of the segment; and

wherein

the sculpting tool is directed into the workpiece in accordance with the transformed three dimensional coordinates to form a mirror image corporeal model of the segment corresponding to the mirror image three dimensional representation.

11. The method of claim 10, further comprising:

displaying a visual representation of the mirror image three dimensional representations of the segment defined by the transformed three dimensional coordinates; and

selectively adjusting the transformed three dimensional coordinates; and

wherein;

the sculpting tool is directed into the workpiece in accordance with the transformed and selectively adjusted three dimensional coordinates.

12. The method of claim 1 wherein:

the generated set of three dimensional coordinates defines a three dimensional mold cavity representation of the selected structure; and

further comprising

directing the sculpting tool into the workpiece to form a mold cavity in accordance with the three dimensional mold cavity representation;

casting a corporeal model replica of the selected structure defined by the mold cavity.

13. The method of claim 1 wherein:

representations of the substance are obtained for spaced locations defining surfaces of structures; and

the generated set of three dimensional coordinates includes coordinates of spaced locations defining a three dimensional representation of the surface of the selected structure; and

further comprising

interpolating locations of the surface of the selected structure intermediate to the spaced locations and generating from said interpolations of the intermediate locations three dimensional coordinates defining the surface of the selected structure at locations between spaced locations; and

wherein

the sculpting tool is directed into the workpiece in accordance with the three dimensional coordinates of the spaced locations and of the interpolated locations.

14. A method of fabricating a three dimensional corporeal model of a selected structure internal to a body by a sculpting tool from three dimensional coordinates defining a three dimensional representation of said selected structure, said data obtained by subjecting the selected structure within the body to radiant energy selected to be productive of selected radiant energy responses that are characteristic of substances and detectable at the exterior of said body, detecting the radiant energy responses to obtain representations of the selected structure, and generating from the representations the three dimensional coordinates, comprising:

directing the sculpting tool into a workpiece in accordance with the generated three dimensional coordinates to form a corporeal model corresponding to the three dimensional representation of the selected structure.

15. The method of claim 14 wherein:

the generated three dimensional coordinates data define a three dimensional mold cavity representation of the selected structure; and

further comprising

directing the sculpting tool into the workpiece to form a mold cavity in accordance with the three dimensional mold cavity representation;

casting a material replica of the selected structure defined by the mold cavity.

16. The method of claim 14 wherein:

representations of the substances are obtained for spaced locations defining surfaces of structures;

the generated three dimensional coordinates include coordinates of spaced locations defining a three dimensional representation of the surface of the selected structure; and

further comprising

interpolating locations of the surface of the selected structure intermediate to the spaced locations and generating from said interpolations of the intermediate locations three dimensional coordinates defining the surface of the selected structure at locations between spaced locations; and

wherein

the sculpting tool is directed into the workpiece in accordance with the three dimensional coordinates of the spaced locations and of the interpolated locations.

17. A method of generating three dimensional coordinates for directing a sculpting tool to form a three dimensional corporeal model of a structure internal to a body, comprising:

subjecting the body to radiant energy to produce radiant energy responses internal to said body that are characteristic of substances and detectable at the exterior the body;

detecting produced radiant energy responses to obtain representations of substances at locations internal to the body defining structures internal to the body three dimensionally; and

generating from the representations of the substances three dimensional coordinates defining a three dimensional representation of a selected structure internal of the body, the three dimensional coordinates generated for directing the sculpting tool into a workpiece to form a corporeal model corresponding to the three dimensional representation of the selected structure.

18. The method of claim 17 wherein the generated three dimensional coordinates define an altered three dimensional representation of the selected structure.

19. The method of claim 17, further comprising:

displaying a visual representation of the selected structure defined by the generated three dimensional coordinates; and

selectively adjusting the three dimensional coordinates; and

wherein

the three dimensional coordinates generated for directing the sculpting tool correspond to the adjusted three dimensional coordinates.

20. The method of claim 19 wherein transformed three dimensional coordinates are generated from the obtained representation of the substances to define an altered three dimensional representation of the selected structure;

a visual representation of altered three dimensional representation of the selected structure is displayed; and

the transformed three dimensional coordinates are selectively adjusted.

21. The method of claim 17 wherein the generated three dimensional coordinates define a three dimensional mold cavity representation of the selected structure.

22. The method of claim 17 wherein:

representations of the substances are obtained for spaced locations defining surfaces of structures; and

the generated three dimensional coordinates include coordinates of spaced locations defining a three dimensional representation of the surface of the selected structure; and

further comprising

interpolating locations of the surface of the selected structure intermediate to the spaced locations and generating from said interpolations of the intermediate locations three dimensional coordinates defining the surface of the selected structure at locations between spaced locations; and

wherein

the three dimensional coordinates generated for directing the sculpting tool include the three dimensional coordinates generated from the interpolations of the intermediate locations.

23. A method of fabricating a three dimensional corporeal model of selected tissue structure internal to an anatomy, comprising:

subjecting the anatomy to radiant energy to produce radiant energy responses internal to said anatomy that are characteristic of tissue structure of said anatomy and that are detectable at the exterior of said anatomy at a plurality of locations each of which is along a path extending in a different selected direction relative to the selected tissue structure;

detecting produced radiant energy responses at the exterior of the anatomy at selected locations of the plurality of locations to obtain representations of the selected tissue structure that are definitive of a selected three dimensional representation thereof;

generating from the obtained representations of the selected tissue structure selected three dimensional coordinates defining the selected three dimensional representation of the selected tissue structure; and

directing a sculpting tool into a workpiece in accordance with the generated selected three dimensional coordinates to form a corporeal model corresponding to the selected three dimensional representation of the selected tissue structure.

24. The method of claim 23 wherein transformed three dimensional coordinates are generated from the obtained representations of the selected tissue structure to define an altered selected three dimensional representation of the selected tissue structure.

25. The method of either claim 23 or claim 24, further comprising:

displaying a visual representation of the selected tissue structure defined by the three dimensional coordinates generated from the obtained representations;

selectively adjusting the generated three dimensional coordinates to define the selected three dimensional representation of the selected tissue structure; and

wherein

the sculpting tool is directed into the workpiece in accordance with the adjusted three dimensional coordinates.

26. The method of claim 23 as arranged to fabricate a surgically implantable prosthesis type corporeal model of a selected skeletal tissue structure of a mammalian anatomy wherein:

the mammalian anatomy is subjected to radiant energy to produce radiant energy responses at locations definitive of the surgically implantable prosthesis to be fabricated; and

the generated three dimensional coordinates define a three dimensional representation of the surgically implantable prosthesis.

27. The method of claim 26 wherein the sculpting tool is directed into the workpiece to form the surgically implantable prosthesis.

28. The method of claim 26 wherein:

the generated three dimensional coordinates define a three dimensional mold cavity representation of the surgically implantable prosthesis; and

the sculpting tool is directed into the workpiece to form a mold cavity in accordance with the three dimensional mold cavity representation; and

further comprising

casting a surgically implantable prosthesis defined by the mold cavity.

29. A method of fabricating a prosthesis representative of a selected tissue structure internal to a mammalian anatomy, comprising:

subjecting the anatomy to radiant energy;

detecting exterior of said anatomy, resulting radiant energy responses produced at a plurality of parallel planes distributed at spaced locations in a selected direction relative to the said anatomy, the radiant energy selected to produce radiant energy responses internal to said anatomy that are characteristic of tissue structure of the anatomy and that are detectable from the exterior of said anatomy, the anatomy subjected to the radiant energy and resulting radiant energy responses detected to be productive of selected representations of the structure internal to the anatomy definitive of the prosthesis to be fabricated;

generating from the selected representations of the structure internal to the anatomy selected three dimensional coordinates defining a selected representation of the prosthesis; and

directing a sculpting tool into the workpiece in accordance with the generated selected three dimensional coordinates to form the selected representation of the prosthesis.

30. The method of claim 29 wherein the selected representation of the prosthesis is a replica of the selected tissue structure.

31. The method of claim 29 wherein:

the generated three dimensional coordinates define a three dimensional mold cavity representation of the prosthesis; and

the sculpting tool is directed into the workpiece to form a mold cavity in accordance with the three dimensional mold cavity representation; and

further comprising

casting a prosthesis defined by the mold cavity.