Method for generating patient-specific implants

• US 6,932,842 B1
• Filed: 05/10/2000
• Issued: 08/23/2005
• Est. Priority Date: 05/11/1999
• Status: Expired due to Fees

• Current Assignee: 3DI GmbH
• Original Assignee: 3DI GmbH
• Inventors: Henning, Torsten, Fried, Wolfgang, Litschko, Peter, Beinemann, Jörg, Linss, Werner
• Primary Examiner(s): Shaver, Kevin
• Assistant Examiner(s): RAMANA, ANURADHA
• Application Number:
  US10/009,881
• Time in Patent Office: 1,931 Days
• Field of Search: 623/16.11, 623/901, 623/908, 433/213, 433/24, 433172-176, 433/201.1, 700 95- 98
• US Class Current: 623/16.11
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/2875 Skull or cranium A61F2/2803 and A61F2/3099 take precedence
• CPC Class Codes: A61F 2/30 Joints
• CPC Class Codes: A61F 2002/30772 Apertures or holes, e.g. of circular cross section
• 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: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35016 Analyse model, decide on number of sections to take
• CPC Class Codes: G05B 2219/35062 Derive mating, complementary, mirror part from computer model data
• CPC Class Codes: G05B 2219/35533 Use, input 2-D data, sectional profile to machine 3-D surface
• CPC Class Codes: G05B 2219/49008 Making 3-D object with model in computer memory
• CPC Class Codes: Y10S 623/901 Method of manufacturing prosthetic device

Abstract

An implant is generated which is functionally and aesthetically adapted to the patient with a greater degree of precision, irrespective of the size, form and complexity of the defect, whereby the implant can be produced and operatively inserted into the patient over a short time period and in a simple manner. A virtual three-dimensional model of the patient which is formed from existing recorded (two-dimensional) image data of the patient is compared with real medical reference data. The comparison which is, for example, carried out using a data bank with test person data enables a reference model object which is most suited to the patient or closest to the patient model to be selected or formed and a virtual implant model is generated accordingly. Computer numeric control data is directly generated from the implant model which is generated virtually in the computer for program-assisted production of the implant.

Claims

1. Method for manufacturing a patient-specific implant, comprising:

obtaining medical two-dimensional image data of a defect area in a patient requiring an implant and an environment thereof for a patient by a method selected from the group consisting of computer tomography (CT) and nuclear magnetic resonance (NMR) tomography;

using a mathematical image processing algorithm to form a surface using the two-dimensional image data;

performing a segmentation to detect bones and hard tissue ranges;

generating a virtual three-dimensional model from the image data of at least the defect area in the patient requiring an implant and the environment thereof;

comparing the virtual three-dimensional model to real medical reference data;

selecting from the real medical reference data a set of said reference data best suited for the patient and forming a three-dimensional reference model object therefrom, the step of selecting the set of said reference data best suited for the patient and forming a reference model object therefrom comprising;

first selecting a plurality of sets of the reference data and forming a corresponding plurality of three-dimensional reference model objects therefrom most resembling the patient considering mathematical, functional, medical and aesthetic parameters; and

then selecting one of said plurality of three-dimensional reference model objects best suited for the patient;

generating a virtual implant model from said selected one of said plurality of three-dimensional reference model objects by superimposing said selected one of said plurality of three-dimensional reference model objects with the virtual three-dimensional model; and

manufacturing the implant by computer numeric control based on data from the virtual implant model.

2. Method as claimed in claim 1, wherein the real medical reference data comprise a database.

3. Method as claimed in claim 1 or 2, wherein the real medical reference data comprises data from the patient.

4. Method as claimed in claim 1, wherein the virtual implant model is a three-dimensional virtual implant model.

5. Method as claimed in claim 1, wherein the selection of one of said plurality of three-dimensional reference model objects best suited for the patient is made in consideration of an expert medical opinion.

6. Method for manufacturing a patient-specific implant, comprising:

obtaining medical two-dimensional image data of a defect area in a patient requiring an implant and an environment thereof for a patient by a method selected from the group consisting of computer tomography (CT) and nuclear magnetic resonance (NMR) tomography;

using a mathematical image processing algorithm to form a surface using the two-dimensional image data;

performing a segmentation to detect bones and hard tissue ranges;

generating a virtual three-dimensional model from the image data of at least the defect area in the patient requiring an implant and the environment thereof;

comparing the virtual three-dimensional model to real medical reference data;

selecting from the real medical reference data a set of said reference data best suited for the patient and forming a three-dimensional reference model object therefrom, the step of selecting the set of said reference data best suited for the patient and forming a reference model object therefrom comprising;

first selecting a plurality of three-dimensional reference model objects similar to the virtual three-dimensional model considering mathematical, functional, medical and aesthetic parameters; and

then selecting one of said plurality of three-dimensional reference model objects best suited for the patient;

generating a virtual implant model from said selected one of said plurality of three-dimensional reference model objects by superimposing said selected one of said plurality of three-dimensional reference model objects with the virtual three-dimensional model; and

manufacturing the implant by computer numeric control based on data from the virtual implant model.

7. Method as claimed in claim 6, wherein the real medical reference data comprise a database.

8. Method as claimed in claim 6, wherein the real medical reference data comprises data from the patient.

9. Method as claimed in claim 6, wherein the virtual implant model is a three-dimensional implant model.

10. Method as claimed in claim 6, wherein the selection of one of said plurality of three-dimensional reference model objects best suited for the patient is made in consideration of an expert medical opinion.