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

• US 8,906,107 B2
• Filed: 11/11/2011
• Issued: 12/09/2014
• 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:
  US13/294,564
• Publication Number:
  US 20120232670A1
• Time in Patent Office: 1,124 Days
• Field of Search: 623 2014- 2036, 606/86.R, 128/898
• US Class Current: 623/20.35
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1764 for the knee
• 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: 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 2/384 hinged, i.e. with transverse axle restricting the movement
• 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 2/5046 for designing or making customized prostheses, e.g. using templates, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2002/30324 differing in thickness
• CPC Class Codes: A61F 2002/30327 differing in diameter
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/3895 unicompartimental
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

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 designing, in a computer system, a femoral implant for repairing a knee joint of a patient, comprising:

obtaining patient-specific data from the patient including image data of the knee joint of the patient;

deriving from the image data varying radii in a first plane of a femoral condyle of the knee joint of the patient; and

designing the femoral implant having a condylar portion, wherein at least a portion of the joint-facing surface of the condylar portion has a sagittal curvature that substantially matches the derived varying radii in the first plane.

2. The method of claim 1, wherein the patient-specific data includes one or more parameters of the patient'"'"'s biological features selected from the group consisting of:

one or more anatomical structures, anatomical axes, biomechanical axes, alignment, kinematics, soft tissue balance, soft tissue impingement of the knee joint of the patient, one or more bone properties of the patient, demographic data of the patient, and any combination thereof.

3. The method of claim 1, wherein the step of deriving includes modifying the joint-facing sagittal curvature of the femoral condyle of the knee joint of the patient.

4. The method of claim 3, wherein the step of modifying includes correcting an abnormality in an existing sagittal J-curve of the femoral condyle of the knee joint of the patient.

5. The method of claim 4, wherein the abnormality is selected from the group consisting of an arthritic flattening of the patient'"'"'s corresponding femoral condyle, one or more subchondral cysts, and one or more osteophyte formations, and any combination thereof.

6. The method of claim 3, wherein the step of modifying including modifying an existing sagittal J-curve of the femoral condyle of the knee joint of the patient to improve an existing feature of the patient'"'"'s biology.

7. The method of claim 6, wherein the existing feature of the patient'"'"'s biology includes one or more of a deformity of the knee joint, an alignment of the knee joint, a trochlear shape of the knee joint, a ligament of the knee joint, kinematics of the knee joint, biomechanics of the knee joint, joint-line location of the knee joint, and joint-gap width of the knee joint.

8. The method of claim 1, further including deriving from the patient-specific data a joint-facing coronal curvature of the femoral condyle of the knee joint of the patient, wherein at least a portion of the joint-facing surface of the condylar portion has a coronal curvature that substantially matches the derived joint-facing coronal curvature.

9. The method of claim 1, further including designing or selecting a single radius of at least a portion of the joint-facing surface of the condylar portion of the femoral implant.

10. The method of claim 1, further including designing a bone-facing surface substantially opposite the joint-facing surface of the femoral implant, wherein the bone-facing surface includes one or more facets configured to abut a resected surface of a corresponding femoral condyle of the knee joint of the patient.

11. The method of claim 10, further including designing or selecting a resectioning strategy for preparing the resected surface.

12. The method of claim 1, wherein the femoral implant is configured to replace both medial and lateral femoral condyles of the knee joint of the patient, and includes a corresponding medial condylar portion and a corresponding lateral condylar portion.

13. The method of claim 12, wherein a joint-facing surface of the corresponding medial condylar portion has a sagittal curvature derived from the patient-specific data.

14. The method of claim 12, wherein a joint-facing surface of the corresponding lateral condylar portion has a sagittal curvature derived from the patient-specific data.

15. The method of claim 1, wherein the femoral implant is configured to replace a medial or a lateral femoral condyle of the knee joint of the patient, and includes a corresponding medial condylar portion or a corresponding lateral condylar portion.

16. The method of claim 15, wherein a joint-facing surface of the corresponding medial or lateral condylar portion has a sagittal curvature derived from the patient-specific data.

17. The method of claim 1 further including designing an M-L width of a condylar portion of the femoral implant to a corresponding M-L width of a femoral condyle of the knee joint of the patient.

18. A method of creating, using a computer system a femoral implant for repairing a knee joint of a patient, comprising:

obtaining patient-specific data from the patient including image data of the knee joint of the patient;

deriving from the image data a joint-facing shape of a femoral condyle of the knee joint of the patient; and

selecting a femoral implant having a condylar portion, wherein at least a portion of the joint-facing surface of the condylar portion has a sagittal curvature that approximates a sagittal curvature of the derived joint-facing shape of the femoral condyle.

19. The method of claim 18, further including modifying the sagittal curvature of the selected femoral implant to substantially match a sagittal curvature of the derived joint-facing shape of the femoral condyle.

20. The method of claim 18, further including deriving an M-L width of a corresponding femoral condyle of the knee joint of the patient and configuring an M-L width of the condylar portion of the femoral implant to match the derived M-L width.

21. A method of designing an articular repair system for repairing a joint of a patient, comprising:

obtaining electronic image data of the joint of the patient;

deriving, from the electronic image data, varying curvatures of at least a portion of an articular surface of the joint of the patient, wherein the varying curvatures are in a first plane;

designing an articular repair system having a corresponding articular surface portion that includes the varying curvatures in a corresponding first plane, wherein the articular repair system has a single radius in a second plane.

22. The method of claim 21, wherein the single radius is derived from the electronic image data.

23. The method of claim 21, wherein the first plane is selected from the group consisting of an anteroposterior plane, a mediolateral plane, a superoinferior plane, and any combination thereof.

24. The method of claim 21, wherein the second plane is selected from the group consisting of an anteroposterior plane, a mediolateral plane, a superoinferior plane, and any combination thereof.

25. The method of claim 21, wherein the joint of the patient is a knee joint, wherein the second plane is a mediolateral plane.