Patient-modified implant

• US 8,486,150 B2
• Filed: 04/07/2011
• Issued: 07/16/2013
• Est. Priority Date: 04/17/2007
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: White, John R., Metzger, Robert, Berend, Keith R.
• Primary Examiner(s): Sweet, Thomas
• Assistant Examiner(s): STEWART, JASON-DENNIS NEILKEN
• Application Number:
  US13/081,618
• Publication Number:
  US 20110184526A1
• Time in Patent Office: 831 Days
• Field of Search: 623 2014- 2021, 623 2032- 2035
• US Class Current: 623/20.21
• CPC Class Codes: A61B 17/154 for preparing bone for knee prosthesis
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1742 for the hip
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 17/1778 for the shoulder
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• 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 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3836 Special connection between upper and lower leg, e.g. constrained
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/3868 with sliding tibial bearing
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/4684 Trial or dummy prostheses
• CPC Class Codes: A61F 2002/30616 Sets comprising a plurality of prosthetic parts of different sizes or orientations
• CPC Class Codes: A61F 2002/30878 with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30884 Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/30892 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 2002/3096 : trimmed or cut to a customised size
• CPC Class Codes: Y10S 623/901 : Method of manufacturing prosthetic device

Abstract

An orthopedic implant includes a first portion including at least one feature modified to be patient-specific and match the anatomy of a specific patient from a three-dimensional digital image of a patient'"'"'s joint using computer modeling. The orthopedic implant includes a non-custom inner bone-engaging surface including a plurality of planar surfaces configured for engagement with non-custom bone cuts.

Claims

1. A method for manufacturing an orthopedic implant, comprising:

constructing a three-dimensional digital image of a patient'"'"'s joint using computer modeling;

obtaining a digital image of a femoral implant having a non-custom inner bone-engaging surface including a plurality of planar surfaces configured for engagement with standard size femoral bone cuts prepared for a non-custom femoral implant;

modifying the digital image of the femoral implant by configuring an anterior femoral flange of the femoral implant to have a patient-specific shape and size and to closely match a corresponding portion of a femur of a specific patient based on the three-dimensional image of the patient'"'"'s joint; and

manufacturing the femoral implant based on the digital image.

2. The method of claim 1, further comprising modifying the digital image of the femoral implant by configuring the anterior flange of the femoral implant to have a patient-specific height that is based on the three-dimensional image of the patient'"'"'s joint.

3. The method of claim 1, wherein obtaining the digital image of the femoral implant includes creating the digital image.

4. The method of claim 1, wherein obtaining the digital image of the femoral implant includes selecting the femoral implant from a plurality of femoral implants having different non-custom sizes based on a size of the patient'"'"'s joint.

5. The method of claim 1, further comprising overlaying the digital image of the femoral implant on the three-dimensional image of the patient'"'"'s joint.

6. A method for manufacturing an orthopedic implant, comprising:

constructing a three-dimensional digital image of a patient'"'"'s joint using computer modeling;

obtaining a digital image of a femoral implant having a non-custom inner bone-engaging surface including a plurality of planar surfaces configured for engagement with standard size femoral bone cuts prepared for a non-custom femoral implant;

modifying the digital image of the femoral implant by configuring an orientation of a patella track of the femoral implant to have a patient-specific shape and size and to closely match a corresponding portion of a femur of a specific patient based on the three-dimensional image of the patient'"'"'s joint; and

manufacturing the femoral implant based on the digital image.

7. The method of claim 6, further comprising modifying the digital image of the femoral implant by configuring the patella track of the femoral implant to be oriented at a patient-specific angle with respect to a medial/lateral centerline of the orthopedic implant based on the three-dimensional image of the patient'"'"'s joint.

8. The method of claim 6, wherein obtaining the digital image of the femoral implant includes creating the digital image.

9. The method of claim 6, wherein obtaining the digital image of the femoral implant includes selecting the femoral implant from a plurality of femoral implants having different non-custom sizes based on a size of the patient'"'"'s joint.

10. The method of claim 6, further comprising overlaying the digital image of the femoral implant on the three-dimensional image of the patient'"'"'s joint.

11. A method for manufacturing an orthopedic implant, comprising:

constructing a three-dimensional digital image of a patient'"'"'s joint using computer modeling;

obtaining a digital image of a femoral implant having a non-custom inner bone-engaging surface including a plurality of planar surfaces configured for engagement with standard size femoral bone cuts prepared for a non-custom femoral implant;

modifying the digital image of the femoral implant by configuring a depth of a patella track of the femoral implant to have a patient-specific shape and size and to closely match a corresponding portion of a femur of a specific patient based on the three-dimensional image of the patient'"'"'s joint; and

manufacturing the femoral implant based on the digital image.

12. The method of claim 11, wherein obtaining the digital image of the femoral implant includes creating the digital image.

13. The method of claim 11, wherein obtaining the digital image of the femoral implant includes selecting the femoral implant from a plurality of femoral implants having different non-custom sizes based on a size of the patient'"'"'s joint.

14. The method of claim 11, further comprising overlaying the digital image of the femoral implant on the three-dimensional image of the patient'"'"'s joint.

15. A method for manufacturing an orthopedic implant, comprising:

constructing a three-dimensional digital image of a patient'"'"'s joint using computer modeling;

obtaining a digital image of a tibial tray including a non-custom locking mechanism couplable with a non-custom tibial bearing;

modifying the digital image of the tibial tray by configuring a peripheral surface of the tibial tray to be patient-specific and to closely match a corresponding peripheral surface of a tibia of a specific patient based on the three-dimensional digital image of the patient'"'"'s joint; and

manufacturing the tibial tray based on the digital image.

16. The method of claim 15, wherein obtaining the digital image of the tibial tray includes creating the digital image.

17. The method of claim 15, wherein obtaining the digital image of the tibial tray includes selecting the tibial tray from a plurality of tibial trays having different non-custom sizes based on a size of the patient'"'"'s joint.

18. The method of claim 15, further comprising overlaying the digital image of the tibial tray on the three-dimensional image of the patient'"'"'s joint.

19. The method of claim 15, wherein the non-custom locking mechanism includes a plurality of recesses on the tibial tray.

20. The method of claim 15, further comprising:

obtaining a digital image of a tibial bearing couplable with the locking mechanism of the tibial tray;

modifying the digital image of the tibial bearing by configuring a peripheral surface of the tibial bearing to be patient-specific and to closely match a corresponding peripheral surface of the tibia of the specific patient based on the three-dimensional digital image of the patient'"'"'s joint; and

manufacturing the tibial bearing based on the digital image of the tibial bearing.