Arthroplasty system and related methods

• US 8,545,509 B2
• Filed: 09/21/2009
• Issued: 10/01/2013
• Est. Priority Date: 12/18/2007
• Status: Active Grant

• Current Assignee: Howmedica Osteonics Corp. (Stryker Corporation)
• Original Assignee: Otismed Corporation (Stryker Corporation)
• Inventors: Park, Ilwhan, Chi, Charlie W., Howell, Stephen M.
• Primary Examiner(s): Truong, Kevin T
• Assistant Examiner(s): BATES, DAVID W
• Application Number:
  US12/563,809
• Publication Number:
  US 20100049195A1
• Time in Patent Office: 1,471 Days
• Field of Search: 606/99, 606/87, 606/88, 700/98
• US Class Current: 606/88
• CPC Class Codes: A61B 17/15 Guides therefor arrangements for guiding straight saw blades in general B23D51/025
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1703 using imaging means, e.g. by X-rays
• CPC Class Codes: A61B 17/1725 for applying transverse screws or pins through intramedullary nails or pins
• CPC Class Codes: A61B 17/1739 specially adapted for particular parts of the body
• CPC Class Codes: A61B 17/1742 for the hip
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2034/104 Modelling the effect of the tool, e.g. the effect of an implanted prosthesis or for predicting the effect of ablation or burring
• CPC Class Codes: A61B 2034/105 Modelling of the patient, e.g. for ligaments or bones
• CPC Class Codes: A61B 2034/107 Visualisation of planned trajectories or target regions
• 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: A61B 34/25 User interfaces for surgical systems
• CPC Class Codes: A61B 5/055 involving electronic [EMR] or nuclear [NMR] magnetic resonance, e.g. magnetic resonance imaging
• CPC Class Codes: A61B 5/4504 Bones A61B5/4547 takes precedence
• CPC Class Codes: A61B 5/4514 Cartilage
• CPC Class Codes: A61B 5/4533 Ligaments
• CPC Class Codes: A61B 5/4585 Evaluating the knee
• CPC Class Codes: A61B 6/03 : Computed tomography [CT] echo-tomography A61B8/14
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: G06T 2207/30008 : Bone
• CPC Class Codes: G06T 7/0012 : Biomedical image inspection
• CPC Class Codes: G06T 7/13 : Edge detection
• CPC Class Codes: G06T 7/30 : Determination of transform parameters for the alignment of images, i.e. image registration

Abstract

A method of manufacturing an arthroplasty jig is disclosed herein. The method may include the following: generate a bone model, wherein the bone model includes a three dimensional computer model of at least a portion of a joint surface of a bone of a patient joint to undergo an arthroplasty procedure; generate an implant model, wherein the implant model includes a three dimensional computer model of at least a portion of a joint surface of an arthroplasty implant to be used in the arthroplasty procedure; assess a characteristic associated with the patient joint; generate a modified joint surface of the implant model by modifying at least a portion of a joint surface of the implant model according to the characteristic; and shape match the modified joint surface of the implant model and a corresponding joint surface of the bone model.

Claims

1. A method of manufacturing an arthroplasty jig, the method comprising utilizing a computer processing device to perform the operations of:

a.) generate a bone model, wherein the bone model includes a three dimensional computer model of at least a portion of a joint surface of a bone of a patient joint to undergo an arthroplasty procedure;

b.) generate an implant model, wherein the implant model includes a three dimensional computer model of at least a portion of a joint surface of an arthroplasty implant to be used in the arthroplasty procedure;

c.) assess a characteristic associated with the patient joint, the characteristic being at least one of a shape of a condyle surface of the patient joint or a joint gap spacing of the patient joint;

d.) generate a modified joint surface of the implant model by modifying at least a portion of a joint surface of the implant model according to the characteristic;

e.) shape match the modified joint surface of the implant model and a corresponding joint surface of the bone model; and

f.) employ data obtained from operation e.) in the manufacture the arthroplasty jig.

2. The method of claim 1, further comprising determining at least one of a location and orientation of a surgical cut plane relative to the implant model, wherein the surgical cut plane is associated with the implant model.

3. The method of claim 2, wherein the surgical cut plane corresponds to a distal resection to be made in the bone of the patient, wherein the bone is a femur.

4. The method of claim 2, wherein the surgical cut plane corresponds to a proximal resection to be made in the bone of the patient, wherein the bone is a tibia.

5. The method of claim 1, wherein the arthroplasty implant is at least one of a TKR or partial knee implant.

6. The method of claim 1, wherein the patient joint is at least one of an ankle, knee, hip, wrist, elbow, shoulder, vertebra-vertebra interface, vertebra-sacrum interface, and vertebra-skull interface.

7. The method of claim 1, wherein the bone is at least one of a femur and tibia.

8. The method of claim 1, wherein the joint surface of the bone includes a condyle articular surface.

9. The method of claim 8, wherein the joint surface of the arthroplasty implant includes a condyle articular surface.

10. The method of claim 1, wherein the bone model is representative of the at least a portion of the joint surface of the bone of the patient joint in a pre-deteriorated state.

11. The method of claim 1, wherein the characteristic includes a cartilage thickness of a generally non-deteriorated side of the patient joint.

12. The method of claim 11, wherein the modifying of the at least a portion of the joint surface of the implant model includes shifting the at least a portion of the joint surface of the implant model by the cartilage thickness.

13. The method of claim 12, wherein the shift is in a direction towards an interior of the implant model.

14. The method of claim 13, wherein the arthroplasty implant is a femur implant and the shift is at least one of anterior and proximal.

15. The method of claim 14, wherein the modified joint surface is associated with a posterior portion of an articular surface of a condyle of the femur implant, and the corresponding joint surface is associated with a posterior portion of an articular surface of a femur condyle of the bone model.

16. The method of claim 13, wherein the arthroplasty implant is a tibia implant and the shift is at least distal.

17. The method of claim 16, wherein the modified joint surface is associated with an articular surface of a condyle of the tibia implant, and the corresponding joint surface is associated with an articular surface of a tibia condyle of the bone model.

18. The method of claim 1, Wherein the characteristic includes a joint gap distance of a generally non-deteriorated side of the patient joint.

19. The method of claim 18, wherein the modifying of the at least a portion of the joint surface of the implant model includes shifting the at least a portion of the joint surface of the implant model by at least a portion of the joint gap distance.

20. The method of claim 19, wherein the at least a portion of the joint gap distance is approximately half of the joint gap distance.

21. The method of claim 19, wherein the joint gap distance is in a distal-proximal direction between opposed condylar articular surfaces of a femur and tibia.

22. The method of claim 19, wherein the shift is in a direction towards the interior of the implant model.

23. The method of claim 22, wherein the arthroplasty implant is a femur implant and the shift is at least one of anterior and proximal.

24. The method of claim 23, wherein the modified joint surface is associated with a posterior portion of an articular surface of a condyle of the femur implant, and the corresponding joint surface is associated with a posterior portion of an articular surface of a femur condyle of the bone model.

25. The method of claim 24, wherein the arthroplasty implant is a tibia implant and the shift is at least distal.

26. The method of claim 25, wherein the modified joint surface is associated with an articular surface of a condyle of the tibia implant, and the corresponding joint surface is associated with an articular surface of a tibia condyle of the bone model.

27. The method of claim 1, wherein the condyle surface that the characteristic pertains to includes at least one of a medial or lateral condyle surface of the joint.

28. The method of claim 1, wherein the condyle surface that the characteristic pertains to includes medial and lateral condyle surfaces of the joint, and the characteristic further pertains to asymmetries between the medial and lateral condyle surfaces of the joint.

29. The method of claim 28, wherein the characteristic further pertains to an offset difference between the medial and the lateral condyle surfaces of the joint.

41. The method of claim 1, wherein the bone model is representative of the knee joint surface of a patient femur in a pre-degenerated state.

30. A method of manufacturing an arthroplasty jig, the method comprising utilizing a computer processing device to perform the operations of:

a.) generate a bone model, wherein the bone model includes a three dimensional computer model of at least a portion of a knee joint surface of a patient femur to undergo an arthroplasty procedure;

b.) identify at least one of a most distal point and a most posterior point of a condyle articular surface of the bone model;

c.) generate an implant model, wherein the implant model includes a three dimensional computer model of at least a portion of a joint surface of a femoral arthroplasty knee implant to be used in the arthroplasty procedure;

d.) identify at least one of a most distal point and a most posterior point of a condyle articular surface of the implant model;

e.) move at least one of the bone model and the implant model so the at least one of the most distal point and the most posterior point of the condyle articular surface of the bone model generally positionally correspond with the at least one of the most distal point and the most posterior point of the condyle articular surface of the implant model; and

f.) employ data obtained from operation e.) in the manufacture the arthroplasty jig.

31. The method of claim 30, further comprising shape match the condyle articular surface of the bone model and the articular condyle surface of the implant model.

32. The method of claim 31, further comprising determining at least one of a location and orientation of a surgical cut plane relative to the implant model, wherein the surgical cut plane is associated with the implant model.

33. The method of claim 32, wherein the surgical cut plane corresponds to a distal resection to be made in the patient femur.

34. The method of claim 30, wherein identifying a most posterior point in step b includes defining an asymptotic line or plane along an anterior side of a femoral shaft of the bone model.

35. The method of claim 34, wherein identifying a most posterior point in step b further includes applying, in a tangential fashion to a posterior region of the articular condyle surface of the bone model, a line or plane generally parallel to a most proximal portion of the asymptotic line or plane.

36. The method of claim 30, wherein identifying a most distal point in step b includes defining an asymptotic line or plane along at least one of a medial side and a lateral side of a femoral shaft of the bone model.

37. The method of claim 36, wherein identifying a most distal point in step b further includes applying, in a tangential fashion to a distal region of the articular condyle surface of the bone model, a line or plane generally perpendicular to a most proximal portion of the asymptotic line or plane.

38. The method of claim 30, wherein identifying a most distal point in step b includes defining a trochlear groove plane of the bone model and applying, in a tangential fashion to a distal region of the articular condyle surface of the bone model, a plane generally perpendicular to the trochlear groove plane.

39. The method of claim 30, wherein identifying a most posterior point in step b includes defining a trochlear groove plane of the bone model and applying, in a tangential fashion to a posterior region of the articular condyle surface of the bone model, a plane generally perpendicular to the trochlear groove plane.

40. The method of claim 30, wherein the arthroplasty implant is at least one of a TKR or partial knee implant.