Customized prosthesis and method of designing and manufacturing a customized prosthesis by utilizing computed tomography data

• US 6,944,518 B2
• Filed: 09/18/2003
• Issued: 09/13/2005
• Est. Priority Date: 09/18/2003
• Status: Active Grant

• Current Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Inventors: Roose, Jeffrey
• Primary Examiner(s): Gandhi, Jayprakash N.
• Assistant Examiner(s): CABRERA, ZOILA E
• Application Number:
  US10/664,540
• Publication Number:
  US 20050065628A1
• Time in Patent Office: 726 Days
• Field of Search: 700/97, 700/98, 700/118, 700/119, 700/182, 700/117, 623/22.4, 623/22.31, 623/22.36, 623/22.32, 623/914, 623/16, 623/22, 623 2221- 2228
• US Class Current: 700/117
• CPC Class Codes: A61B 17/86 Pins or screws or threaded wires; nuts therefor A61B17/72 take precedence
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• 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 2/34 Acetabular cups
• CPC Class Codes: A61F 2002/30578 having apertures, e.g. for receiving fixation screws
• CPC Class Codes: A61F 2002/30616 Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30708 Means for distinguishing between left-sided and right-sided devices, Sets comprising both left-sided and right-sided prosthetic parts
• CPC Class Codes: A61F 2002/30784 Plurality of holes
• CPC Class Codes: A61F 2002/30785 parallel
• 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 2002/3446 Single cups
• CPC Class Codes: A61F 2250/0084 Means for distinguishing between left-sided and right-sided devices; Sets comprising both left-sided and right-sided prosthetic parts
• CPC Class Codes: A61F 2310/00023 Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• 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: G16H 20/40 relating to mechanical, radiation or invasive therapies, e.g. surgery, laser therapy, dialysis or acupuncture
• CPC Class Codes: G16H 30/40 for processing medical images, e.g. editing
• CPC Class Codes: G16H 50/50 for simulation or modelling of medical disorders
• CPC Class Codes: G16Z 99/00 : Subject matter not provided for in other main groups of this subclass

Abstract

A method of making an acetabular prosthesis includes acquiring a first set of data defining in three dimensions at least a portion of a bone of a patient. A second set of data is computed based upon the first set of data. The prosthesis is manufactured to include an acetabular cup and an attachment part extending therefrom. The manufacturing step includes the step of forming the attachment part based on the second set of data.

Claims

1. A method of making an acetabular prosthesis comprising the steps of:

acquiring a first set of data defining in three dimensions at least a portion of a bone of a patient;

computing a second set of data based upon the first set of data; and

manufacturing said prosthesis to include an acetabular cup and an attachment part extending therefrom configured to attach the acetabular cup to bone surrounding the acetabulum of a patient,

wherein said manufacturing step includes the step of forming said attachment part based on the second set of data.

2. The method of claim 1, wherein said second set of data defines in three dimensions said attachment part.

3. The method of claim 1, wherein:

said attachment part comprises a flange extending from said acetabular cup, and

said flange has defined therein a number of throughholes configured to receive an anchoring element.

4. The method of claim 1, wherein said manufacturing step further includes the steps of:

forming said attachment part to include a bone-facing surface and a tissue-facing surface, and

forming said tissue-facing surface to be a partial facsimile of a surface of said bone.

5. The method of claim 4, wherein said manufacturing step further includes the step of forming said bone-facing surface to possess a shape complementary to a portion of the surface of said bone.

6. The method of claim 1, wherein:

said attachment part possesses a cup interface end portion and a free end portion, and

said forming step includes forming said attachment part with a uniform thickness extending from said cup interface end portion to said free end portion.

7. The method of claim 1, wherein said manufacturing step further includes the steps of

forming said attachment part to include a bone-facing surface and a tissue-facing surface, and

forming said bone-facing surface to possess a shape complementary to a portion of a surface of said bone.

8. The method of claim 1, further comprising the step of acquiring a third set of data defining in three dimensions other bone structure of the patient, at least some of said other bone structure contralaterally corresponding to said bone of the patient, wherein:

said manufacturing step includes the step of arranging an angular orientation of said acetabular cup relative to at least one of said attachment part and the bone of the patient based on said third set of data.

9. A method of making a prosthesis for a joint socket comprising the steps of:

acquiring a first set of data defining in three dimensions at least a portion of a bone of a patient;

computing a second set of data based upon the first set of data; and

manufacturing said prosthesis to include a functional part and an attachment part extending therefrom configured to attach the functional part to the bone surrounding the joint socket,

wherein said manufacturing step includes the step of forming said attachment part based on the second set of data.

10. The method of claim 9, wherein said second set of data defines in three dimensions said attachment part.

11. The method of claim 9, wherein:

said attachment part comprises a flange extending from said functional part, and

said flange has defined therein a number of throughholes configured to receive an anchoring element.

12. The method of claim 9, wherein said manufacturing step further includes the steps of:

forming said attachment part to include a bone-facing surface and a tissue-facing surface, and

forming said tissue-facing surface to be a partial facsimile of a surface of said bone.

13. The method of claim 12, wherein said manufacturing step further includes the step of forming said bone-facing surface to possess a shape complementary to a portion of the surface of said bone.

14. The method of claim 13, wherein:

said attachment part possesses a cup interface end portion and a free end portion, and

said attachment part possesses a uniform thickness extending from said cup interface end portion to said free end portion.

15. The method of claim 9, wherein said manufacturing step further includes the steps of:

forming said attachment part to include a bone-facing surface and a tissue-facing surface, and

forming said bone-facing surface to possess a shape complementary to a portion of a surface of said bone.

16. The method of claim 9, further comprising the step of acquiring a third set of data defining in three dimensions other bone structure of the patient, at least some of said other bone structure contralaterally corresponding to said bone of the patient, wherein:

said manufacturing step includes the step of arranging an angular orientation of said functional part relative to at least one of said attachment part and the bone of the patient based on said third set of data.

17. The method of claim 9, wherein said manufacturing step includes manufacturing said functional part from pre-determined data.

18. A method of making an acetabular prosthesis comprising the steps of:

acquiring a first set of data defining in three dimensions at least a portion of a bone of a patient;

computing a second set of data based upon the first set of data;

manufacturing said prosthesis to include an acetabular cup and an attachment part extending therefrom configured to attach the acetabular cup to bone surrounding the acetabulum of a patient, wherein said manufacturing step includes the steps of;

forming said attachment part based on the second set of data,

forming said attachment part to include a bone-facing surface and a tissue-facing surface, and

forming said tissue-facing surface to be a partial facsimile of a surface of said bone.

19. The method of claim 18, wherein said second set of data defines in three dimensions said attachment part.

20. The method of claim 18, wherein:

said attachment part comprises a flange extending from said acetabular cup, and

said flange has defined therein a number of throughholes configured to receive an anchoring element.

21. The method of claim 18, further comprising the step of acquiring a third set of data defining in three dimensions other bone structure of the patient, at least some of said other bone structure contralaterally corresponding to said bone of the patient, wherein:

said manufacturing step includes the step of arranging an angular orientation of said acetabular cup relative to at least one of said attachment part and the bone of the patient based on said third set of data.

22. An acetabular prosthesis, comprising:

an acetabular cup; and

a flange attached to said acetabular cup and configured to attach the acetabular cup to bone surrounding the acetabulum of a patient, said flange is prepared by a process including the steps of;

acquiring a first set of data defining in three dimensions at least a portion of a bone of a patient;

computing a second set of data based upon the first set of data; and

manufacturing said flange based upon the second set of data.

23. The prosthesis of claim 22, wherein said second set of data defines in three dimensions said flange.

24. The prosthesis of claim 22, wherein said flange has defined therein a number of throughholes configured to receive an anchoring element.

25. The prosthesis of claim 22, wherein said manufacturing step further includes the steps of:

forming said flange to include a bone-facing surface and a tissue-facing surface, and

forming said tissue-facing surface to be a partial facsimile of a surface of said bone.

26. The prosthesis of claim 25, wherein said manufacturing step further includes the step of forming said bone-facing surface to possess a shape complementary to a portion of the surface of said bone.

27. The prosthesis of claim 22, wherein:

said flange possesses a cup interface end portion and a free end portion, and

said flange possesses a uniform thickness extending from said cup interface end portion to said free end portion.

28. The prosthesis of claim 22, wherein said manufacturing step further includes the steps of:

forming said flange to include a bone-facing surface and a tissue-facing surface, and

forming said bone-facing surface to possess a shape complementary to a portion of a surface of said bone.

29. The prosthesis of claim 22, wherein the process further comprises the step of acquiring a third set of data defining in three dimensions other bone structure of the patient, at least some of said other bone structure contralaterally corresponding to said bone of the patient, and wherein said manufacturing step includes the step of arranging an angular orientation of said acetabular cup relative to at least one of said flange and the bone of the patient based on said third set of data.

30. A method of making an acetabular prosthesis comprising the steps of:

acquiring a first set of data defining in three dimensions at least a portion of a bone of a patient;

computing a second set of data based upon the first set of data; and

manufacturing said prosthesis to include an integral component including an acetabular cup and an attachment part extending therefrom,

wherein said manufacturing step includes the step of forming said attachment part based on the second set of data.

31. The method of claim 30 wherein the integral component of the manufactured prosthesis is monolithic.