Patient-specific numerically controlled instrument

• US 8,715,289 B2
• Filed: 04/15/2011
• Issued: 05/06/2014
• Est. Priority Date: 04/15/2011
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Smith, Aaron P.
• Primary Examiner(s): BATES, DAVID W
• Application Number:
  US13/087,854
• Publication Number:
  US 20120265208A1
• Time in Patent Office: 1,117 Days
• Field of Search: 606/87, 606/89, 606/91
• US Class Current: 606/87
• CPC Class Codes: A61B 17/1626 Control means; Display units
• CPC Class Codes: A61B 17/1668 for the upper femur A61B17/164 takes precedence
• CPC Class Codes: A61B 17/1684 for the shoulder
• CPC Class Codes: A61B 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 17/1742 for the hip
• CPC Class Codes: A61B 17/175 for preparing the femur for hip prosthesis insertion
• CPC Class Codes: A61B 17/1778 for the shoulder
• CPC Class Codes: A61B 17/56 Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
• CPC Class Codes: A61B 2017/1602 Mills
• CPC Class Codes: A61B 2017/564 Methods for bone or joint treatment
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A medical device for preparing a bone of a joint of a patient includes a numerically controlled instrument having a housing including a controller, a processor and a tool driver, a patient-specific reference guide removably couplable to the housing, and a cutting tool removably coupled to the tool driver. The patient-specific reference guide has a three-dimensional inner surface preoperatively configured to mirror and mate with a corresponding surface of a bone of a joint of a patient in only one position. The patient-specific reference guide is configured to automatically register the numerically controlled instrument to the patient'"'"'s bone portion intraoperatively. The cutting tool is movable along a patient-specific tool path determined during the preoperative plan for preparing a portion of the bone.

Claims

1. A medical device for preparing a bone of a joint of a patient comprising:

a miniaturized numerically controlled instrument having a housing, the housing including a controller, a processor, a guide connector, and a tool driver;

a patient-specific reference guide having a connecting portion removably coupled to the guide connector of the housing, wherein the patient-specific reference guide has a three-dimensional inner surface preoperatively configured from preoperative scans of the bone of the joint conducted as part of a preoperative plan to mirror and mate with a corresponding surface of the bone of the joint of the patient in only one position, the inner surface configured to automatically register the numerically controlled instrument to the patient'"'"'s bone intraoperatively; and

a cutting tool removably coupled to the tool driver, the cutting tool movable within the tool driver by the controller along a patient-specific tool path determined during the preoperative plan for preparing a portion of the bone of the patient while the guide connector of the housing is mounted on the connecting portion of the patient-specific reference guide;

wherein the processor converts the patient-specific tool path to signals for the controller; and

wherein the controller operates the tool driver from the signals.

2. The medical device of claim 1, wherein the bone is a proximal femoral bone and the inner surface of the reference guide is a shell-like structure configured to mate with a portion of a femoral head of the proximal femoral bone.

3. The medical device of claim 2, wherein the patient-specific tool path is determined during the preoperative plan to remove a bony growth of a femoral neck of the patient.

4. The medical device of claim 3, wherein the bony growth is a femoral acetabular impingement defect on the femoral neck, and the reference guide is configured and dimensioned to leave the bony growth exposed and to provide clearance for a motion of the cutting tool.

5. The medical device of claim 1, wherein the bone is an acetabulum and the reference guide is configured for the acetabulum of the patient.

6. The medical device of claim 5, wherein the reference guide is an annular ring and the inner surface of the reference guide is configured to mate and conform to an annular area around a rim of the acetabulum.

7. The medical device of claim 6, wherein the guide connector and connecting portion include a plurality of connecting adaptors.

8. A medical device for preparing an acetabulum of a patient comprising:

a miniaturized numerically controlled instrument having a housing, the housing including a controller, a processor, a guide connector, and a tool driver;

a patient-specific reference guide having a connecting portion removably couplable to the guide connector of the housing, wherein the patient-specific reference guide has a three-dimensional inner surface preoperatively configured from preoperative scans of the acetabulum conducted as part of a preoperative plan to mirror and mate with a corresponding surface of the acetabulum of the patient in only one position and the inner surface configured to automatically register the numerically controlled instrument to the patient'"'"'s bone intraoperatively, wherein the reference guide is an annular ring and the inner surface of the reference guide is configured to mate and conform to an annular area around a rim of the acetabulum, wherein the housing is coupled to the reference guide with a plurality of connecting adaptors, wherein each connecting adaptor is removably coupled to a corresponding bone screw passing through a corresponding hole of the reference guide for securing the reference guide to the acetabulum; and

a cutting tool removably coupled to the tool driver, the cutting tool movable within the tool driver by the controller along a patient-specific tool path determined during the preoperative plan for preparing a portion of the acetabulum of the patient;

wherein the processor converts the patient-specific tool path to signals for the controller; and

wherein the controller operates the tool driver from the signals.

9. A medical device for preparing a femur of a patient comprising:

a miniaturized numerically controlled instrument having a housing, the housing including a controller, a processor, a guide connector, and a tool driver;

a patient-specific femoral reference guide having a connecting portion removably coupled to the guide connector of the housing, wherein the femoral reference guide has a three-dimensional inner surface preoperatively configured from preoperative scans of the femur to mirror and mate to a corresponding surface of a femoral head of the patient in only one position, the inner surface configured to automatically register the numerically controlled instrument to the patient'"'"'s femoral head intraoperatively; and

a cutting tool removably coupled to the tool driver, the cutting tool movable within the tool driver by the controller along a patient-specific tool path determined during the preoperative plan for removing a femoral acetabular impingement defect from a femoral neck of the patient while the guide connector of the housing is supported on the connecting portion of the patient-specific femoral reference guide;

wherein the processor converts the patient-specific tool path to signals for the controller; and

wherein the controller operates the tool driver from the signals.

10. The medical device of claim 9, wherein the patient-specific tool path is determined during the preoperative plan to remove a femoral acetabular impingement defect.

11. The medical device of claim 10, wherein the femoral reference guide is configured and dimensioned to leave the femoral acetabular impingement defect exposed and to provide clearance for a motion of the cutting tool.

12. A medical device for preparing a bone of a joint of a patient comprising:

a miniaturized numerically controlled instrument having a housing, the housing including a guide connector and a tool driver, the tool driver configured to drive a cutting tool; and

a patient-specific reference guide having a connecting portion removably coupled to the guide connector of the housing, wherein the patient-specific reference guide has a three-dimensional surface preoperatively configured from preoperative scans of the bone of the joint conducted as part of a preoperative plan to mirror and mate with a corresponding surface of the bone of the patient in only one position, the three-dimensional surface configured to automatically register the numerically controlled instrument to the patient'"'"'s bone intraoperatively, wherein the tool driver is configured to move the cutting tool along a patient-specific tool path determined during the preoperative plan for preparing a portion of the bone of the patient while the guide connector of the housing is supported on the connecting portion of the patient-specific reference guide.

13. The medical device of claim 12, wherein the numerically controlled instrument further includes a controller configured to control the tool driver.

14. The medical device of claim 13, wherein the numerically controlled instrument further includes a power supply for powering the numerically controlled instrument.

15. The medical device of claim 12, wherein the bone is a proximal femoral bone and a surface of the reference guide is a shell-like structure configured to nestingly mate with a portion of a femoral head of the proximal femoral bone.

16. The medical device of claim 12, wherein the bone is an acetabulum and the reference guide is configured for the acetabulum of the patient, wherein the reference guide is an annular rim and the surface of the reference guide is configured to mate and conform to an annular area around a rim of the acetabulum.

17. A medical device for preparing an acetabulum of a patient comprising:

a miniaturized numerically controlled instrument having a housing, the housing including a guide connector and a tool driver, the tool driver configured to drive a cutting tool; and

a patient-specific reference guide having a connecting portion removably couplable to the guide connector of the housing, wherein the patient-specific reference guide has a three-dimensional surface preoperatively configured from preoperative scans of the acetabulum conducted as part of a preoperative plan to mirror and mate with a corresponding surface of the acetabulum of the patient in only one position and to automatically register the numerically controlled instrument to the patient'"'"'s acetabulum intraoperatively, wherein the tool driver is configured to move the cutting tool along a patient-specific tool path determined during the preoperative plan for preparing a portion of the acetabulum of the patient, wherein the reference guide is an annular rim and the three-dimensional surface of the reference guide is configured to mate and conform to an annular area around a rim of the acetabulum, and wherein the guide connector and the coupling portion are coupled with a plurality of connecting adapters, wherein each connecting adapter is removably coupled to a corresponding bone screw passing through a corresponding hole of the reference guide for securing the reference guide to the acetabulum.