Patient-specific pelvic implants for acetabular reconstruction

• US 8,597,365 B2
• Filed: 08/04/2011
• Issued: 12/03/2013
• Est. Priority Date: 08/04/2011
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Meridew, Jason D.
• Primary Examiner(s): Willse, David H
• Assistant Examiner(s): BLANCO, JAVIER G
• Application Number:
  US13/197,851
• Publication Number:
  US 20130035766A1
• Time in Patent Office: 852 Days
• Field of Search: None
• US Class Current: 623/22.32
• CPC Class Codes: A61F 2/30734 Modular inserts, sleeves or augments, e.g. placed on proximal part of stem for fixation purposes or wedges for bridging a bone defect
• 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 2/34 Acetabular cups
• CPC Class Codes: A61F 2002/30131 horseshoe- or crescent- or C-shaped or U-shaped
• CPC Class Codes: A61F 2002/30156 triangular
• CPC Class Codes: A61F 2002/30176 V-shaped
• CPC Class Codes: A61F 2002/30281 wedge-shaped
• CPC Class Codes: A61F 2002/30433 using additional screws, bolts, dowels, rivets or washers e.g. connecting screws
• CPC Class Codes: A61F 2002/305 Snap connection
• CPC Class Codes: A61F 2002/30576 with extending fixation tabs
• CPC Class Codes: A61F 2002/30578 having apertures, e.g. for receiving fixation screws
• CPC Class Codes: A61F 2002/30736 Augments or augmentation pieces, e.g. wedges or blocks for bridging a bone defect
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/3401 with radial apertures, e.g. radial bores for receiving fixation screws
• CPC Class Codes: A61F 2002/3403 Polar aperture
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A pelvic implant includes a first surface including a recess configured for receiving a portion of a flange of an acetabular cage and a patient-specific second surface opposite to the first surface. The patient-specific second surface is preoperatively configured from a three-dimensional digital image of a pelvis of a patient to mate and closely conform to a corresponding surface of the pelvis under the flange in only one position.

Claims

1. A method of making a pelvic implant comprising:

using a three-dimensional digital image of said pelvis of the patient measuring patient-specific anatomical features of the pelvis of the patient;

customizing an acetabular cage implantable into a pelvis of a patient;

the acetabular cage including an acetabular cup and a plurality of flanges couplable to an upper portion of the acetabular cup; and

customizing a plurality of patient-specific spacers, wherein each patient-specific spacer comprises a first surface and opposed and second surface, and a peripheral surface located between the first and second surfaces, wherein the first surface has a recess receiving a complementary-shaped portion of a corresponding flange of the plurality of flanges, wherein the second surface defines a patient-specific bone-engaging surface preoperatively configured from the three-dimensional digital image of the pelvis of the patient to complementary mate and closely conform to mirror a corresponding surface of the pelvis under the flange in only one position,

wherein the peripheral surface includes a ridge surrounding the recess that is elevated relative to the first surface,

wherein each patient-specific spacer of the plurality of patient-specific spacers have a selected shape and each shape corresponds to the complementary-shaped of the corresponding flange,

wherein at least one flange of the plurality of flanges includes an iliac flange and at least one patient-specific spacer of the plurality of patient-specific spacers includes an iliac spacer couplable to the iliac flange.

2. The method of claim 1, wherein customizing the plurality of patient-specific spacers including forming a recess of the iliac spacer to have an elongated rectangular shape.

3. The method of claim 1, wherein customizing the plurality of patient-specific spacers including forming a recess of the iliac spacer to have a square shape.

4. The method of claim 1, wherein customizing the acetabular cage includes providing the plurality of flanges to include an ischial flange couplable to the upper portion of the acetabular cup.

5. The method of claim 4, wherein customizing the plurality of patient-specific spacers includes providing an ischial flange having a recess that is a triangular shape.

6. The method of claim 1, further comprising:

providing an ischial flange as one of the plurality of flanges; and

providing an ischial spacer as one of the plurality of patient-specific spacers.

7. The method of claim 1, further comprising:

providing at least one flange of the plurality of flanges to be removably couplable to the acetabular acetabular cup.

8. The method of claim 1, further comprising:

providing an ischial blade modularly couplable to the acetabular cup.

9. The method of claim 1, further comprising:

providing an obturator foramen hook modularly couplable to the acetabular cup.

10. The method of claim 1, wherein at least one patient-specific spacer has variable thickness.

11. The method of claim 1, wherein customizing the plurality of patient-specific spacers includes providing a varied thickness among the plurality of patient-specific spacers.

12. The method of claim 11, wherein customizing the acetabular cage includes providing at least one of flanges of the plurality of flanges to engage the outer slot.

13. The method of claim 1, wherein customizing the acetabular cage includes forming at least one outer slot in the acetabular cup.

14. The method of claim 1, further comprising:

forming a bore into the patient-specific spacers.