Patient-adapted and improved orthopedic implants, designs and related tools

• US 8,556,983 B2
• Filed: 03/09/2011
• Issued: 10/15/2013
• Est. Priority Date: 05/25/2001
• Status: Expired due to Term

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Bojarski, Raymond A., Chao, Nam, Slamin, John, Lang, Philipp, Fitz, Wolfgang, Steines, Daniel
• Primary Examiner(s): Philogene, Pedro
• Application Number:
  US13/044,413
• Publication Number:
  US 20110295378A1
• Time in Patent Office: 951 Days
• Field of Search: 623/23.46, 623/20.36, 623/20.34, 623/20.35, 623/20.29, 623/14.12, 623/20.32, 623/20.3, 295/92, 600/410, 600/595, 606/86.R
• US Class Current: 623/20.35
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61F 2/30 Joints
• 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 2/3859 Femoral components
• CPC Class Codes: A61F 2/3886 for stabilising knees against anterior or lateral dislocations
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/461 of knees
• CPC Class Codes: A61F 2002/30322 differing in surface structures
• CPC Class Codes: A61F 2002/30324 differing in thickness
• CPC Class Codes: A61F 2002/30326 differing in height or in length
• CPC Class Codes: A61F 2002/30327 differing in diameter
• 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 2250/0036 differing in thickness
• CPC Class Codes: A61F 2250/0039 differing in diameter
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture

Abstract

Methods and devices are disclosed relating improved articular models, implant components, and related guide tools and procedures. In addition, methods and devices are disclosed relating articular models, implant components, and/or related guide tools and procedures that include one or more features derived from patient-data, for example, images of the patient'"'"'s joint. The data can be used to create a model for analyzing a patient'"'"'s joint and to devise and evaluate a course of corrective action. The data also can be used to create patient-adapted implant components and related tools and procedures.

Claims

1. A method of selecting and/or designing a patient-matched articular implant having an outer articular surface and an inner bone-facing surface, the method comprising the steps of

(a) preoperatively identifying from patient-specific data of the patient'"'"'s joint a curvature on an articular surface of the patient'"'"'s joint;

(b) selecting for the articular implant'"'"'s outer articular surface a curvature that substantially matches the curvature identified in step (a), or a predetermined percentage thereof;

(c) selecting a desired minimum thickness for the articular implant;

(d) selecting and/or designing one or more surface facets on the inner, bone-facing surface of the articular implant that provide at least the desired minimum thickness selected in step (c) between the one or more surface facets and the articular surface curvature selected in step (b).

2. The method of claim 1, wherein the articular implant is selected from the group consisting of a femoral implant, a tibial implant, a patellar implant, a hip implant, a shoulder implant, and a spinal implant.

3. The method of claim 1, wherein the articular implant is a femoral implant.

4. The method of claim 1, wherein designing the implant comprises computer-aided design (CAD) and computer-aided manufacturing (CAM).

5. The method of claim 1, wherein designing comprises altering a blank.

6. The method of claim 1, wherein the substantially matching includes smoothing a line or curve derived from the patient'"'"'s articular surface.

7. The method of claim 1, wherein selecting the desired minimum thickness for the articular implant includes performing a finite element analysis (FEA).

8. The method of claim 1, further including performing a load-bearing analysis of the patient'"'"'s joint.

9. A method for making an implant for repairing a joint of a patient that meets a minimal thickness threshold, the method comprising the steps of:

(a) identifying a desired minimal thickness threshold for the implant;

(b) deriving from patient-specific data regarding the joint of the patient a substantially coronal curvature or substantially sagittal curvature for the articular surface of the implant; and

(c) modifying the coronal or sagittal curvature in order for the implant to be within the minimal thickness threshold.

10. The method of claim 9, wherein modifying the coronal or sagittal curvature comprises increasing the radius of curvature.

11. The method of claim 9, further comprising, in step (a), identifying a threshold maximum implant thickness, and in step (c) modifying the coronal or sagittal curvature in order for the implant to be within the maximum thickness threshold.

12. The method of claim 9, wherein identifying the desired minimal thickness threshold for the implant includes performing a finite element analysis (FEA).

13. The method of claim 9, further including performing a load-bearing analysis of the joint of the patient.

14. The method of claim 11, wherein identifying the desired maximum thickness threshold for the implant includes performing a finite element analysis (FEA).

15. The method of claim 11, further including performing a load-bearing analysis of the joint of the patient.

16. A method for making an implant for repairing a joint of a patient that meets a maximum thickness threshold, the method comprising the steps of:

(a) identifying a desired maximum thickness threshold for the implant;

(b) deriving from patient-specific data regarding the joint of the patient a coronal or sagittal curvature for a condylar articular surface of the implant; and

(c) modifying the coronal or sagittal curvature in order for the implant to be within the maximum thickness threshold.

17. The method of claim 16, wherein modifying the coronal or sagittal curvature comprises increasing the radius of curvature.

18. The method of claim 16, further comprising, in step (a), identifying a threshold minimal implant thickness, and in step (c), modifying the coronal or sagittal curvature in order for the implant to be within the minimal thickness threshold.