Arthroplasty devices and related methods

• US 8,460,302 B2
• Filed: 12/18/2006
• Issued: 06/11/2013
• Est. Priority Date: 12/18/2006
• Status: Active Grant

• Current Assignee: Howmedica Osteonics Corp. (Stryker Corporation)
• Original Assignee: Otismed Corporation (Stryker Corporation)
• Inventors: Park, Ilwhan, Chi, Charlie W.
• Primary Examiner(s): Truong, Kevin T
• Assistant Examiner(s): BECCIA, CHRISTOPHER J
• Application Number:
  US11/641,382
• Publication Number:
  US 20080147072A1
• Time in Patent Office: 2,367 Days
• Field of Search: 606 86 R- 89, 700/98, 409/2, 409/3, 409/6, 409/7, 409/79, 409/80, 409/175, 409/219, 409/224, 409/227, 409/289, 409/291, 409/292
• US Class Current: 606/87
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 17/8863 Apparatus for shaping or cutting osteosynthesis equipment by medical personnel
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

Methods and apparatuses for forming customized arthroplasty jigs are disclosed. Some of the apparatuses may comprise a plurality of rapid production machines and an automated mechanical system. The automated mechanical system may be configured to transport a first arthroplasty jig blank to a first rapid production machine and a second arthroplasty jig blank to a second rapid production machine. The first rapid production machine may be configured to form a first arthroplasty jig from the first arthroplasty jig blank, and the second rapid production machine may be configured to form a second arthroplasty jig from the second arthroplasty jig blank, the second arthroplasty jig having a different configuration from the first arthroplasty jig.

Claims

1. A method of manufacturing a plurality of customized arthroplasty jigs, the method comprising:

activating an automated mechanical system in an apparatus comprising the automated mechanical system, an arthroplasty jig blank storage site comprising a plurality of arthroplasty jig blanks and a plurality of rapid production machines, so that the automated mechanical system physically transports a first arthroplasty jig blank from the arthroplasty jig blank storage site to a first rapid production machine that is configured to machine a first arthroplasty jig from the first arthroplasty jig blank, and so that the automated mechanical system physically transports a second arthroplasty jig blank from the arthroplasty jig blank storage site to a second rapid production machine that is configured to machine a second arthroplasty jig from the second arthroplasty jig blank,

wherein the first and second arthroplasty jigs have different configurations, and

wherein the automated mechanical system is a robot.

2. The method of claim 1, wherein the automated mechanical system physically transports the first arthroplasty jig blank to the first rapid production machine prior to physically transporting the second arthroplasty jig blank to the second rapid production machine.

3. The method of claim 1, wherein the first and second rapid production machines comprise computer numerical control machines.

4. The method of claim 1, wherein the apparatus comprises eight rapid production machines.

5. The method of claim 1, wherein the automated mechanical system is in communication with a computer.

6. The method of claim 5, wherein the computer provides the automated mechanical system with first machining instructions for machining the first arthroplasty jig.

7. The method of claim 6, wherein the computer provides the automated mechanical system with second machining instructions for machining the second arthroplasty jig.

8. The method of claim 7, wherein the automated mechanical system communicates the first machining instructions to the first rapid production machine so that the first rapid production machine can machine the first arthroplasty jig.

9. The method of claim 8, wherein the automated mechanical system communicates the second machining instructions to the second rapid production machine so that the second rapid production machine can machine the second arthroplasty jig.

10. The method of claim 1, wherein the method comprises producing at least 30 customized arthroplasty jigs per hour.

11. The method of claim 1, wherein the rapid production machines are arranged in rows.

12. The method of claim 1, wherein the rapid production machines are arranged in a circle.

13. The method of claim 1, wherein the automated mechanical system removes the first arthroplasty jig from the first rapid production machine when machining of the first arthroplasty jig has been completed.

14. The method of claim 13, wherein the automated mechanical system transports the first arthroplasty jig from the first rapid production machine to a station that is configured to clean arthroplasty jigs.

15. The method of claim 14, wherein the station also is configured to package the arthroplasty jigs after they have been cleaned.

16. The method of claim 13, wherein the automated mechanical system transports the second arthroplasty jig from the second rapid production machine when machining of the second arthroplasty jig has been completed.

17. A method of manufacturing a plurality of customized arthroplasty jigs, the method comprising:

activating an automated mechanical system in an apparatus comprising the automated mechanical system, an arthroplasty jig blank storage site comprising a plurality of arthroplasty jig blanks and a rapid production machine, so that the automated mechanical system physically transports a first arthroplasty jig blank from the arthroplasty jig blank storage site to a first component of the rapid production machine that is configured to machine a first arthroplasty jig from the first arthroplasty jig blank, and so that the automated mechanical system physically transports a second arthroplasty jig blank from the arthroplasty jig blank storage site to a second component of the rapid production machine that is configured to machine a second arthroplasty jig from the second arthroplasty jig blank,

wherein the first and second arthroplasty jigs have different configurations, and

wherein the automated mechanical system is a robot in communication with a computer, the computer providing the automated mechanical system with first machining instructions for machining the first arthroplasty jig.

18. The method of claim 17, wherein the rapid production machine comprises a computer numerical control machine.

19. The method of claim 17, wherein the computer provides the automated mechanical system with second machining instructions for machining the second arthroplasty jig.

20. The method of claim 19, wherein the automated mechanical system communicates the first machining instructions to the first component of the rapid production machine so that the first component can machine the first arthroplasty jig.

21. The method of claim 20, wherein the automated mechanical system communicates the second machining instructions to the second rapid production machine so that the second rapid production machine can machine the second arthroplasty jig.

22. The method of claim 17, wherein the method comprises producing at least 30 customized arthroplasty jigs per hour.