Method of manufacturing of individually formed prothesis or implant

• US 4,704,686 A
• Filed: 05/20/1986
• Issued: 11/03/1987
• Est. Priority Date: 04/10/1982
• Status: Expired due to Fees

• Current Assignee: Gunther Aldinger
• Original Assignee: Gunther Aldinger
• Inventors: Aldinger, Gunther
• Primary Examiner(s): Smith, Jerry
• Assistant Examiner(s): MacDonald, Allen
• Application Number:
  US06/865,551
• Time in Patent Office: 532 Days
• Field of Search: 364/414, 364/468, 623/16, 623/17, 623/18, 623/19, 623/20, 623/21, 623/22, 623/23
• US Class Current: 700/163
• 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 2/3662 Femoral shafts
• CPC Class Codes: A61F 2002/30332 Conically- or frustoconically-shaped protrusion and recess
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/365 Connections of heads to necks
• CPC Class Codes: A61F 2002/369 Stepped shaft, i.e. having discrete diameter changes
• CPC Class Codes: A61F 2220/0033 made by longitudinally pushing a protrusion into a complementary-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2310/00017 Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: Y10S 623/914 Bone

Abstract

A method of producing an individually adjusted endoprothesis pin includes: processing X-ray data of the bone density into a subset of tomographs showing a succession of parallel cross-sections of the bone; selecting from the subset a succession of parallel measuring planes determining from the contours of the bone cavity a structural center line and an antetortion plane of the pin; checking and adjusting desired dimensions of the pin in view of its withdrawal from the bone cavity; and machining a raw sample of the pin to form a succession of parallel disk-shaped steps corresponding in height to the spaces between the parallel planes.

Claims

1. A method of producing an endoprothesis having an anchoring pin individually adjusted to an opening into a cavity of a bone of a patient, comprising the steps of

(a) moving an X-ray or nuclear spin apparatus along the patient'"'"'s bone and measuring transversely to the path of movement a plurality of points of the bone so as to obtain characteristic data, such as bone density, at the respective points;

(b) processing the measured data into a set of true-scale tomographs corresponding to cross-sections of the bone in planes extending transversely to the path of movement of the X-ray or nuclear spin apparatus;

(c) determining in the set of tomographs a subset corresponding to a part of the bone which will receive the anchoring pin;

(d) determining in said subset at least two centroids corresponding to planar centers of gravity at different levels in said bone part whereby a connection line of said centroids defines a structural center line of the endoprothesis;

(e) determining in said subset a succession of superposed planes extending parallel to each other at different levels, and evaluating contours of the bone cavity in said parallel planes;

(f) determining desired dimensions of a contour of the anchoring pin to match the contour of the bone cavity at respective parallel planes, checking the dimensions in view of the withdrawal of the pin from the bone cavity, and readjusting the dimensions to prevent collision of the pin with the contour of said bone opening during the withdrawal of the pin;

(g) storing final values of the desired pin dimensions;

(h) machining a raw sample of the pin in accordance with the stored final values by removing material from circumferential areas of the sample corresponding in height to spaces between the successive parallel planes in said subject whereby the resulting succession of step-like disks machined on the sample are oriented in accordance with said parallel planes.

2. A method as defined in claim 1 further comprising the step of checking and modifying the dimensions of the contour of a bone cavity to be made to such an extent as to avoid overlap of said contours in the parallel planes when viewed in the direction of withdrawal of said pin.

3. A method as defined in claim 1 wherein the spacing between respective parallel planes is selected in dependency on the shape of the bone cavity in the part determined in step (c).

4. A method as defined in claim 1 for producing a hip-bone endoprothesis having an anchoring pin adjusted to the cavity of a thigh bone of a patient, further comprising the steps of

(i) determining in the subset of tomographs after the step (e) an antetorsion direction for the pin by evaluating the largest diameter of a contour of the bone cavity in a base plane selected close to the bone opening;

(j) determining corresponding antetorsion directions in the contours in all remaining parallel planes whereby a plane common to respective antetorsion directions defines an antetorsion plane of the pin;

(k) determining at the contours at respective parallel planes a clearance between opposite tangential lines forming right angles with a corresponding antetorsion direction;

(1) arrangeing the determined successive clearances of respective planes one after the other on true scale in a plan view to check the course of the bone cavity before determining the desired dimensions of the pin in step (f).

5. A method as defined in claim 1 wherein said plurality of points on the patient'"'"'s bone is measured by an X-ray apparatus having screening means, the processing of measured data being made on a computer defining a limit value of density to be processed, said screening means being adjusted to screen out data of low bone density below said limit value.

6. A method as defined in claim 1 wherein said raw sample is a preliminary model and the final pin being produced by casting the machined model.

7. A method as defined in claim 1 wherein said raw sample of the pin is integrally connected between two concentric disc which after the completion of the pin are separated.

8. A method as defined in claim 7 wherein said machining step includes electroerosion.

9. A method as defined in claim 7 wherein said raw sample is produced by pressing or forgering.