Deformable articulating template (formerly: customized orthopaedic implants and related methods)

• US 8,989,460 B2
• Filed: 02/25/2010
• Issued: 03/24/2015
• Est. Priority Date: 02/25/2009
• Status: Active Grant

• Current Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Mahfouz, Mohamed Rashwan
• Primary Examiner(s): Johns, Andrew W
• Application Number:
  US13/203,012
• Publication Number:
  US 20110305379A1
• Time in Patent Office: 1,853 Days
• Field of Search: 382/128, 382/131, 382/154, 128/922, 606/102
• US Class Current: 382/128
• CPC Class Codes: A61B 2034/102 Modelling of surgical devices, implants or prosthesis
• 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 8/4245 involving determining the position of the probe, e.g. with respect to an external reference frame or to the patient
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• 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 2/3601 for replacing only the epiphyseal or metaphyseal parts of the femur, e.g. endoprosthetic femoral heads or necks directly fixed to the natural femur by internal fixation devices non-prosthetic internal fixation devices for the femoral head or neck A61B17/74
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/4003 Replacing only the epiphyseal or metaphyseal parts of the humerus, i.e. endoprosthesis not comprising an entire humeral shaft replacing only the epiphyseal or metaphyseal parts of the femur A61F2/3601
• CPC Class Codes: A61F 2002/30943 using mathematical models
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/3863 Condyles fitted on an anchored base
• CPC Class Codes: A61F 2002/3895 unicompartimental
• CPC Class Codes: G06F 17/18 for evaluating statistical data , e.g. average values, frequency distributions, probability functions, regression analysis forecasting specially adapted for a specific administrative, business or logistic context G06Q10/04
• CPC Class Codes: G06T 19/00 Manipulating 3D models or images for computer graphics
• CPC Class Codes: G06T 2210/41 Medical
• CPC Class Codes: G16H 50/50 for simulation or modelling of medical disorders
• CPC Class Codes: G16Z 99/00 Subject matter not provided for in other main groups of this subclass

Abstract

A method of designing a prosthetic implant. Exemplary methods may include developing a three-dimensional model of an anatomic feature from one or more two-dimensional images. The three-dimensional model may include a plurality of radii of curvature representing the shape of respective portions of a contact surface. In some exemplary embodiments, three-dimensional models associated with a large number members of a population may be utilized to create templates for prosthetic implants. A three-dimensional model of an anatomic feature of a patient may be compared to the available templates, and a suitable template may be tested by virtually implanting the template on the three-dimensional model of the patient'"'"'s anatomical feature. In some embodiments, a patient'"'"'s three-dimensional model for which a suitable pre-made template is not available may be used to customize a pre-made template to design a suitable implant.

Claims

1. A method of generating a patient specific implant based upon unique anatomical features of a patient comprising:

using at least one medical scan of a human anatomical feature from a unique patient to generate a three dimensional electronic representation of the human anatomical feature that incorporate size and curvature features that mimic size and curvature features of the human anatomical feature;

designing a prosthetic implant to imitate the size and curvature features of the human anatomical feature that are specific to the unique patient, including selecting at least one of a three dimensional electronic representation of the patient specific implant from a plurality of prosthetic implant templates; and

virtually test fitting the designed prosthetic implant using the three dimensional electronic representation of the human anatomical feature.

2. The method of claim 1, wherein using the at least one medical scan includes identifying a contact line, dividing the contact line into a plurality of sections, and creating a model of the curvature of the contact line by identifying a radius of curvature corresponding to each section, and incorporating the model into the electronic representation.

3. The method of claim 1 or claim 2, wherein using the at least one medical scan includes identifying a plurality of angularly separated points along the contact line, approximating the surface of the anatomical feature near the contact line using a radius of curvature associated with each point, and incorporating the radii of curvature associated with the points into the electronic representation, where the radii of curvature associated with individual points are representative of the surface of the anatomical feature in a direction generally orthogonal to the contact line.

4. The method of claim 1, wherein designing the prosthetic implant includes designing the prosthetic implant to approximate the model of the contact line.

5. A method of generating a patient specific prosthetic implant, comprising:

using at least one medical scan of a human anatomical feature from a unique patient to generate a three dimensional electronic representation of the human anatomical feature that incorporates size and curvature features mimicking size and contour features of the human anatomical feature;

using the three dimensional electronic representation of the human anatomical feature to select at least one of a plurality of prosthetic implant templates to construct a patient specific implant, at least five of the plurality of prosthetic implants differing from one another in at least one of contour and size;

customizing the selected prosthetic implant template to imitate the size and curvature features of the human anatomical feature that are specific to the unique patient; and

virtually test fitting the customized prosthetic implant using the three dimensional electronic representation of the human anatomical feature.

6. A method of generating a patient specific prosthetic implant, comprising:

generating a three dimensional electronic representation of the human anatomical feature that incorporates size and curvature features mimicking size and contour features of the human anatomical feature using at least one medical scan of a human anatomical feature from a unique patient;

selecting at least one of a three dimensional electronic representation of a plurality of prosthetic implant templates taking into consideration the size and curvature features exhibited by the three dimensional electronic representation of the human anatomical feature;

wherein the step of selecting includes assessing which of the plurality of prosthetic implant templates has the lowest percent deviation from the three dimensional electronic representation of the human anatomical feature.

7. The method of claim 6, wherein the three dimensional electronic representation of the human anatomical feature includes a model of a contact line, the model comprising a plurality radii of curvature, where each radii of curvature is associated with a portion of the contact line.

8. The method of claim 6 or claim 7, wherein the step of selecting includes comparing the radii of curvature associated with the model of the contact line with corresponding radii of curvature associated with at least one of the plurality of prosthetic implant templates.