Orthognathic implant and methods of use

• US 9,381,072 B2
• Filed: 06/05/2015
• Issued: 07/05/2016
• Est. Priority Date: 04/29/2010
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Furrer, Andre, Zillig, Timo, Metzger, Marc Christian
• Primary Examiner(s): SEVILLA, CHRISTIAN ANTHONY
• Application Number:
  US14/731,587
• Publication Number:
  US 20150265378A1
• Time in Patent Office: 396 Days
• US Class Current: 1/1
• CPC Class Codes: A61B 17/151 for corrective osteotomy
• CPC Class Codes: A61B 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 17/1728 for holes for bone plates or plate screws
• CPC Class Codes: A61B 17/1739 specially adapted for particular parts of the body
• CPC Class Codes: A61B 17/176 for the jaw guiding dental drills A61C1/082
• CPC Class Codes: A61B 17/80 Cortical plates , i.e. bone plates; Instruments for holding or positioning cortical plates, or for compressing bones attached to cortical plates
• CPC Class Codes: A61B 17/8061 specially adapted for particular bones A61B17/70 and A61B17/74 take precedence
• CPC Class Codes: A61B 17/8071 for the jaw
• CPC Class Codes: A61B 17/808 Instruments for holding or positioning bone plates, or for adjusting screw-to-plate locking mechanisms
• CPC Class Codes: A61B 17/8085 with pliable or malleable elements or having a mesh-like structure, e.g. small strips A61B17/8071, A61B17/8076 take precedence
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 6/51 for dentistry
• CPC Class Codes: A61C 8/0031 Juxtaosseous implants, i.e. implants lying over the outer surface of the jaw bone
• CPC Class Codes: A61C 8/0089 Implanting tools or instruments
• CPC Class Codes: A61C 9/004 Means or methods for taking digitized impressions
• CPC Class Codes: G05B 19/182 characterised by the machine tool function, e.g. thread cutting, cam making, tool direction control G05B19/21 - G05B19/40 take precedence
• CPC Class Codes: G05B 2219/49023 3-D printing, layer of powder, add drops of binder in layer, new powder
• CPC Class Codes: G16B 5/00 ICT specially adapted for modelling or simulations in systems biology, e.g. gene-regulatory networks, protein interaction networks or metabolic networks

Abstract

An implant for use in orthognathic surgery of a maxilla may include a longitudinal plate member and a plurality of pre-shaped fingers extending from an upper edge of the plate member. The longitudinal plate member is pre-shaped to correspond to the pre-operative shape of the maxilla; and the fingers are pre-shaped to correspond to the shape of the maxilla. The fingers may be pre-shaped to correspond to either the pre-operative shape or the post-operative shape of the maxilla.

Claims

1. A method of customizing a pre-shaped implant for use in orthognathic surgery of a maxilla, the method comprising:

obtaining a pre-operative 3-D model of a patient'"'"'s maxilla in a computer, whereby a first portion of the maxilla and a second portion of the maxilla define a first relative position;

manipulating the pre-operative 3-D model of the maxilla into a planned post-operative shape whereby the first portion of the maxilla and the second portion of the maxilla define a second relative position that is different than the first relative position; and

custom constructing a virtual model of a bone fixation implant to match the planned post-operative shape of the maxilla, the bone fixation implant including a plate member pre-shaped to attach to the first portion of the maxilla, and at least one finger extending from the plate member shaped to attach to the second portion of the maxilla.

2. The method of claim 1, wherein the bone fixation implant is constructed from Titanium.

3. The method of claim 1, further comprising the step of custom constructing a guiding implant to match the pre-operative shape of the patient'"'"'s maxilla, the guiding implant including a plate member defining a plurality of apertures, the apertures being arranged to provide a template for pre-osteotomy drilling of holes in the maxilla.

4. The method of claim 3, wherein the step of custom constructing the guiding implant is performed prior to the step custom constructing the bone fixation implant.

5. The method of claim 1, wherein the obtaining step further comprises scanning the patient'"'"'s maxilla with a 3-D scanning device.

6. The method of claim 5, wherein the 3-D scanning device is a CT scanning device.

7. The method of claim 6, wherein the obtaining step further comprises obtaining raw data of the maxilla in slices of less than 1 mm each, the raw data being arranged to collectively form the 3-D model of the maxilla.

8. The method of claim 7, wherein the obtaining step further comprising obtaining the raw data of the maxilla in slices greater than 0.2 mm.

9. The method of claim 1, further comprising the step of analyzing the 3-D model of the maxilla to determine a cut line for a virtual osteotomy procedure, wherein the analyzing step is performed prior to the manipulating step.

10. The method of claim 9, wherein the analyzing step further comprises the step of performing a virtual osteotomy on the 3-D model of the maxilla at the cut line.

11. The method of claim 10, wherein the analyzing step further comprises the step of custom constructing a virtual model of a guiding implant to match the pre-operative shape of the patient'"'"'s maxilla, the guiding implant including a plate member defining a plurality of apertures that are aligned along the cut line.

12. The method of claim 11, further comprising the step of transferring the virtual model of the guiding implant and the virtual model of the bone fixation implant to a machine that is configured to produce the guiding implant and the bone fixation implant.

13. The method of claim 12, wherein the transferring step further comprises transferring the virtual models to a milling machine.

14. The method of claim 13, further comprising the step of milling the guiding implant from the virtual model of the guiding implant.

15. The method of claim 1, further comprising the step of milling the bone fixation implant from the virtual model of the bone fixation implant.

16. The method of claim 1, further comprising the step of performing a virtual osteotomy on the 3-D model of the maxilla prior to the manipulating step.

17. The method of claim 1, further comprising the step of milling bone fixation implant from the virtual model of the bone fixation implant.