Customized patient-specific instrumentation and method for performing a bone re-cut

• US 8,357,166 B2
• Filed: 09/29/2008
• Issued: 01/22/2013
• Est. Priority Date: 09/30/2007
• Status: Active Grant

• Current Assignee: DePuy Synthes Products LLC (Johnson & Johnson)
• Original Assignee: Depuy Products Incorporated (Johnson & Johnson)
• Inventors: Aram, Luke J., Auger, Daniel D., Rose, Bryan, Beech, Richard
• Primary Examiner(s): Truong, Kevin T
• Assistant Examiner(s): Waggle, Jr., Larry E
• Application Number:
  US12/240,985
• Publication Number:
  US 20090088759A1
• Time in Patent Office: 1,576 Days
• Field of Search: 606/79, 606/86.R, 606 87- 89, 606 96- 98
• US Class Current: 606/88
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: Y10T 409/30084 with regulation of operation by templet, card, or other replaceable information supply

Abstract

A number of orthopedic surgical instruments are also disclosed. A method, apparatus, and system for fabricating such instruments are also disclosed.

Claims

1. A method of performing an orthopaedic surgical procedure on a bone of a patient, comprising:

positioning a customized patient-specific cutting block in contact with the bone of the patient,

inserting a pair of guide pins into a pair of guide pin holes defined in the customized patient-specific cutting block,

inserting a cutting blade of a bone saw into the customized patient-specific cutting block,

making a first cut with the cutting blade in the bone of the patient with the customized patient-specific cutting block,

removing the customized patient-specific cutting block from the bone of the patient without removing the guide pins from the bone of the patient,

inserting the pair of guide pins into a pair of guide pin holes defined in a patient-universal re-cut block after removing the customized patient-specific cutting block from the bone,

inserting the cutting blade into the patient-universal re-cut block, and

making a second cut with the cutting blade in the bone of the patient with the patient-universal re-cut block.

2. The method of claim 1, wherein:

positioning the customized patient-specific cutting block in contact with the bone of the patient comprises positioning the customized patient-specific cutting block in contact with a femur of the patient,

making the first cut in the bone of the patient with the customized patient-specific cutting block comprises making the first cut in the femur of the patient with the customized patient-specific cutting block,

making the second cut in the bone of the patient with the patient-universal re-cut block comprises making the second cut in the femur of the patient with the patient-universal re-cut block, and

the second cut is substantially parallel to the first cut.

3. The method of claim 1, wherein:

positioning the customized patient-specific cutting block in contact with the bone of the patient comprises positioning the customized patient-specific cutting block in contact with a femur of the patient,

making the first cut in the bone of the patient with the customized patient-specific cutting block comprises making the first cut in the femur of the patient with the customized patient-specific cutting block,

making the second cut in the bone of the patient with the patient-universal re-cut block comprises making the second cut in the femur of the patient with the patient-universal re-cut block, and

the second cut is oriented in an angled position relative to the first cut.

4. The method of claim 1, wherein:

positioning the customized patient-specific cutting block in contact with the bone of the patient comprises positioning the customized patient-specific cutting block in contact with a tibia of the patient,

making the first cut in the bone of the patient with the customized patient-specific cutting block comprises making the first cut in the tibia of the patient with the customized patient-specific cutting block,

making the second cut in the bone of the patient with the patient-universal re-cut block comprises making the second cut in the tibia of the patient with the patient-universal re-cut block, and

the second cut is substantially parallel to the first cut.

5. The method of claim 1, wherein:

positioning the customized patient-specific cutting block in contact with the bone of the patient comprises positioning the customized patient-specific cutting block in contact with a tibia of the patient,

making the first cut in the bone of the patient with the customized patient-specific cutting block comprises making the first cut in the tibia of the patient with the customized patient-specific cutting block,

making the second cut in the bone of the patient with the patient-universal re-cut block comprises making the second cut in the tibia of the patient with the patient-universal re-cut block, and

the second cut is oriented in an angled position relative to the first cut.

6. The method of claim 1, wherein:

inserting the pair of guide pins into the pair of guide pin holes defined in the patient-universal re-cut block comprises inserting the pair of guide pins into the pair of guide pin holes defined in the patient-universal re-cut block such that a cutting guide of the patient-universal re-cut block is substantially parallel to the first cut, and

making the second cut in the bone of the patient with the patient-universal re-cut block comprises making the second cut in the bone of the patient with the patient-universal re-cut block such that the second cut is substantially parallel to the first cut.

7. The method of claim 1, wherein:

inserting the pair of guide pins into the pair of guide pin holes defined in the patient-universal re-cut block comprises inserting the pair of guide pins into the pair of guide pin holes defined in the patient-universal re-cut block such that a cutting guide of the patient-universal re-cut block is oriented in an angled position relative to the first cut, and

making the second cut in the bone of the patient with the patient-universal re-cut block comprises making the second cut in the bone of the patient with the patient-universal re-cut block such that the second cut is oriented in an angled position relative to the first cut.

8. The method of claim 1, wherein inserting the pair of guide pins into the pair of guide pin holes defined in the patient-universal re-cut block comprises:

determining an amount of additional bone to be removed from the bone of the patient subsequent to making the first cut in the bone of the patient with the customized patient-specific cutting block,

selecting a pair of guide pin holes which corresponds to the amount of additional bone to be removed from the bone of the patient from a plurality of pairs of guide pin holes, and

inserting the pair of guide pins into the selected pair of guide pin holes which corresponds to the amount of additional bone to be removed from the bone of the patient.

9. A method of performing an orthopaedic surgical procedure on a femur of a patient, comprising:

positioning a customized patient-specific cutting block in contact with the femur of the patient,

inserting a pair of guide pins into a pair of guide pin holes defined in the customized patient-specific cutting block,

inserting a cutting blade of a bone saw into the customized patient specific cutting block

making a first cut with the cutting blade in the femur of the patient with the customized patient-specific cutting block,

removing the customized patient-specific cutting block from the femur of the patient without removing the guide pins from the femur of the patient,

determining an amount of additional bone to be removed from the femur of the patient subsequent to making the first cut in the femur of the patient with the customized patient-specific cutting block,

selecting a pair of guide pin holes defined in a patient-universal re-cut block which corresponds to the amount of additional bone to be removed from the femur of the patient from a plurality of pairs of guide pin holes,

inserting the pair of guide pins into the selected pair of guide pin holes which corresponds to the amount of additional bone to be removed from the femur of the patient after removing the customized patient-specific cutting block from the bone,

inserting the cutting blade into the patient-universal re-cut block, and

making a second cut with the cutting blade in the femur of the patient with the patient-universal re-cut block.

10. The method of claim 9, wherein:

inserting the pair of guide pins into the selected pair of guide pin holes which corresponds to the amount of additional bone to be removed from the femur of the patient comprises inserting the pair of guide pins into the selected pair of guide pin holes which corresponds to the amount of additional bone to be removed from the femur of the patient such that a cutting guide of the patient-universal re-cut block is substantially parallel to the first cut, and

making the second cut in the femur of the patient with the patient-universal re-cut block comprises making the second cut in the femur of the patient with the patient-universal re-cut block such that the second cut is substantially parallel to the first cut.

11. The method of claim 9, wherein:

inserting the pair of guide pins into the selected pair of guide pin holes which corresponds to the amount of additional bone to be removed from the femur of the patient comprises inserting the pair of guide pins into the selected pair of guide pin holes which corresponds to the amount of additional bone to be removed from the femur of the patient such that a cutting guide of the patient-universal re-cut block is oriented in an angled position relative to the first cut, and

making the second cut in the femur of the patient with the patient-universal re-cut block comprises making the second cut in the femur of the patient with the patient-universal re-cut block such that the second cut is oriented in an angled position relative to the first cut.