Arthroplasty devices and related methods

• US 9,017,336 B2
• Filed: 01/19/2007
• Issued: 04/28/2015
• Est. Priority Date: 02/15/2006
• Status: Active Grant

• Current Assignee: Howmedica Osteonics Corp. (Stryker Corporation)
• Original Assignee: Otismed Corporation (Stryker Corporation)
• Inventors: Park, Ilwhan, Howell, Stephen M., Chi, Charlie W.
• Primary Examiner(s): SEVILLA, CHRISTIAN ANTHONY
• Application Number:
  US11/656,323
• Publication Number:
  US 20070226986A1
• Time in Patent Office: 3,021 Days
• Field of Search: 606/79, 606/87, 600/587
• US Class Current: 606/88
• CPC Class Codes: A61B 17/154 for preparing bone for knee prosthesis
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1675 for the knee
• CPC Class Codes: A61B 17/1739 specially adapted for particular parts of the body
• CPC Class Codes: A61B 17/1742 for the hip
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 17/1778 for the shoulder
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 34/70 Manipulators specially adapted for use in surgery
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture

Abstract

Arthroplasty jigs, arthroplasty jig blanks, and related methods and devices are disclosed. Some variations of the methods comprise forming an arthroplasty jig from a near-shape arthroplasty jig blank, where the near-shape arthroplasty jig blank has at least one feature specific to a target site to be matched by the arthroplasty jig. Certain of the methods comprise forming an arthroplasty jig having a first configuration from a near-shape arthroplasty jig blank having a second configuration approximating the first configuration. Some of the methods comprise forming a near-shape arthroplasty jig blank, where the near-shape arthroplasty jig blank is configured to be formed into an arthroplasty jig, and the near-shape arthroplasty jig blank has at least one feature specific to a target site to be matched by the arthroplasty jig.

Claims

1. A method of manufacturing a patient specific arthroplasty jig, the method comprising:

providing a near-shape jig blank to a manufacturing machine, the near-shape jig blank having a first outer surface having a pair of generally orthogonal surfaces, a second outer surface opposite the first outer surface, and a feature that will be retained in the patient specific arthroplasty jig, the feature including a general shape of the near-shape jig blank, the general shape being specific to either a right knee or a left knee;

using the manufacturing machine to create the patient specific arthroplasty jig from the near-shape jig blank by generating in the first outer surface of the near-shape jig blank patient specific features including a matching surface corresponding to an articular surface of a knee of a patient, the matching surface being generated preoperatively using a computer and determined from a preoperative analysis of image data of the articular surface of the knee of the patient, the matching surface being configured to mechanically register to the articular surface; and

using the manufacturing machine to generate in the near-shaped jig blank a saw guiding slot, the saw guiding slot being generated preoperatively.

2. The method of claim 1, wherein the matching surface is generated in the near-shape jig blank by the manufacturing machine via machining.

3. The method of claim 1, wherein the saw guiding slot is generated in the near-shape jig blank by the manufacturing machine via machining.

4. The method of claim 1, wherein the patient specific arthroplasty jig is for total knee arthroplasty.

28. The method of claim 1, wherein the image data is generated from CT or MRI images of the knee of the patient.

33. The method of claim 1, wherein the manufacturing machine is a CNC machine.

5. A method of manufacturing a patient specific arthroplasty jig, the method comprising:

providing a near-shape jig blank to a manufacturing machine, the near-shape jig blank having a first outer surface having a pair of generally orthogonal surfaces, a second outer surface opposite the first outer surface, and a feature that will be retained in the patient specific arthroplasty jig, the feature including a general shape of the near-shape jig blank, the general shape being specific to either a femur or tibia;

using the manufacturing machine to create the patient specific arthroplasty jig from the near-shape jig blank by generating in the first outer surface of the near-shape jig blank patient specific features including a matching surface corresponding to an articular surface of a knee of a patient, the matching surface being generated preoperatively using a computer and determined from a preoperative analysis of image data of the articular surface of the knee of the patient, the matching surface being configured to mechanically register to the articular surface; and

using the manufacturing machine to generate in the near-shaped jig blank a saw guiding slot, the saw guiding slot being generated preoperatively.

6. The method of claim 5, wherein the matching surface is generated in the near-shape jig blank by the manufacturing machine via machining.

7. The method of claim 6, wherein the saw guiding slot is generated in the near-shape jig blank by the manufacturing machine via machining.

8. The method of claim 7, wherein the patient specific arthroplasty jig is for total knee arthroplasty.

29. The method of claim 5, wherein the image data is generated from CT or MRI images of the knee of the patient.

34. The method of claim 5, wherein the manufacturing machine is a CNC machine.

9. A method of manufacturing a patient specific arthroplasty jig, the method comprising:

selecting a size category from an inventory of multiple size categories of near-shape jig blanks based on a dimension associated with a knee of a patient, each jig blank having a first outer surface having a pair of generally orthogonal surfaces, second outer surface opposite the first outer surface, and a feature that will be retained in the patient specific arthroplasty jig;

obtaining a near-shape jig blank from the selected size category;

using a manufacturing machine to create the patient specific arthroplasty jig from the near-shape jig blank by generating in the near-shape jig blank patient specific features including a matching surface corresponding to an articular surface of the knee of the patient, the matching surface being generated preoperatively using a computer and determined from a preoperative analysis of image data of the articular surface of the knee of the patient, the matching surface being configured to mechanically register to the articular surface; and

using the manufacturing machine to generate in the near-shaped jig blank a saw guiding slot, the saw guiding slot being generated preoperatively.

10. The method of claim 9, wherein the matching surface is generated in the near-shape jig blank by the manufacturing machine via machining.

11. The method of claim 9, wherein the saw guiding slot is generated in the near-shape jig blank by the manufacturing machine via machining.

12. The method of claim 9, wherein the patient specific arthroplasty jig is for total knee arthroplasty.

13. The method of claim 9, wherein there are at least six size categories.

14. The method of claim 9, wherein the dimension includes a medial/lateral dimension.

15. The method of claim 9, wherein the dimension includes an anterior/posterior dimension.

16. The method of claim 9, wherein each size category includes orientation categories including a right knee orientation category and a left knee orientation category, the method further comprising preoperatively making a right-left determination of whether the knee of the patient is right or left and using the right-left determination to select an orientation category.

17. The method of claim 16, wherein the obtaining the near-shape jig blank from the selected size category also includes obtaining the near-shape jig blank from the selected orientation category.

18. The method of claim 9, wherein each size category includes bone-type categories including a femur category and a tibia category, the method further comprising preoperatively making a femur-tibia determination of whether the patient specific arthroplasty jig should be a femur jig or a tibia jig and using the femur-tibia determination to select a bone-type category.

19. The method of claim 18, wherein the obtaining the near-shape jig blank from the selected size category also includes obtaining the near-shape jig blank from the selected bone-type category.

30. The method of claim 9, wherein the image data is generated from CT or MRI images of the knee of the patient.

35. The method of claim 9, wherein the manufacturing machine is a CNC machine.

20. A method of manufacturing a patient specific arthroplasty jig, the method comprising:

preoperatively analyzing image data of an articular surface of bone of a patient;

using a computer, preoperatively computer modeling a matching surface corresponding to at least a portion of the articular surface;

providing a near-shape jig blank to a manufacturing machine, the near-shape jig blank having a first outer surface having a pair of generally orthogonal surfaces, a second outer surface opposite the first outer surface, and a feature that will be retained in the patient specific arthroplasty jig, wherein the feature is at least one of;

a) that the near-shape jig blank is only for a right knee or a left knee;

b) that the near-shape jig blank is only for a femur or tibia;

or c) that the near-shape jig blank is only for a certain selected size of jig associated with at least one dimension of the bone; and

using the manufacturing machine to preoperatively create the patient specific arthroplasty jig from the near-shape jig blank by generating in the first outer surface of the near-shape jig blank patient specific features including the matching surface, the matching surface being configured to mechanically register to the at least a portion of the articular surface.

21. The method of claim 20, further comprising using the manufacturing machine to generate in the near-shaped jig blank a saw guiding slot, the saw guiding slot being generated preoperatively.

31. The method of claim 20, wherein the image data is generated from CT or MRI images of the knee of the patient.

36. The method of claim 20, wherein the manufacturing machine is a CNC machine.

22. A method of manufacturing a patient specific arthroplasty jig for use on a knee of a patient, the knee include a medial and a lateral condyle surface, the method comprising:

providing a near-shape jig blank to a manufacturing machine, the near-shape jig blank having a first outer surface having geometrically distinct condyle portions corresponding to the respectively medial and the lateral condyle surfaces; and

using the manufacturing machine to create the patient specific arthroplasty jig from the near-shape jig blank by generating patient specific features in the first outer surface of the near-shape jig blank, the patient specific features including a matching surface corresponding to an articular surface of a knee of a patient, the matching surface being generated preoperatively using a computer and determined from a preoperative analysis of image data of the articular surface of the knee of the patient, the matching surface being configured to mechanically register to the articular surface.

23. The method of claim 22, further comprising generating in the near-shaped jig blank a saw guiding slot the saw guiding slot being generated preoperatively.

24. The method of claim 22, wherein a shape of the geometrically distinct condyle portions of the near-shape jig blank is different for a femur and a tibia.

25. The method of claim 22, wherein a shape of the geometrically distinct condyle portions of the near-shape jig blank is different for a right knee and a left knee.

26. The method of claim 22, further comprising a second outer surface opposite the first outer surface, the second outer surface including a shape configuration that approximates that of the patient specific arthroplasty jig.

27. The method of claim 22, wherein an indent separates the geometrically distinct condyle portions.

32. The method of claim 22, wherein the image data is generated from CT or MRI images of the knee of the patient.

37. The method of claim 22, wherein the manufacturing machine is a CNC machine.