Implant device and method for manufacture

• US 9,517,134 B2
• Filed: 05/22/2014
• Issued: 12/13/2016
• Est. Priority Date: 02/14/2007
• Status: Active Grant

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Lang, Philipp
• Primary Examiner(s): Philogene, Pedro
• Application Number:
  US14/285,151
• Publication Number:
  US 20140250677A1
• Time in Patent Office: 936 Days
• Field of Search: 606 86 R- 89, 606/102, 606/105, 295/92, 623/18.11, 623/20.14, 623/14.12, 623/22.11, 623/19.11, 623/20.35, 623/23.32, 600/587, 600/407, 600/424, 600/427, 600/428
• US Class Current: 1/1
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• 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 2/32 for the hip
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3804 for elbows
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/40 for shoulders
• CPC Class Codes: A61F 2/4202 for ankles
• CPC Class Codes: A61F 2/4225 for feet, e.g. toes
• CPC Class Codes: A61F 2/4241 for hands, e.g. fingers
• CPC Class Codes: A61F 2/4261 for wrists
• CPC Class Codes: A61F 2/44 for the spine, e.g. vertebrae, spinal discs
• CPC Class Codes: A61F 2002/30092 using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2002/30884 Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/30892 parallel
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2002/3097 : using laser
• CPC Class Codes: A61F 2210/0014 : using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2310/00011 : Metals or alloys
• CPC Class Codes: A61F 2310/00017 : Iron- or Fe-based alloys, e.g. stainless steel
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00161 : Carbon; Graphite
• CPC Class Codes: A61F 2310/00167 : Diamond or diamond-like carbon
• CPC Class Codes: A61F 2310/00179 : Ceramics or ceramic-like structures
• CPC Class Codes: A61F 2310/00203 : containing alumina or aluminium oxide
• CPC Class Codes: A61F 2310/00239 : containing zirconia or zirconium oxide ZrO2
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49 : Method of mechanical manufacture

Abstract

Disclosed are systems, devices and methods for optimizing the manufacture and/or production of patient-specific orthopedic implants. The methods include obtaining image data of a patient, selecting a blank implant to be optimized for the patient, and modifying the blank implant utilizing techniques disclosed herein to alter specific features of the implant to conform to the patient'"'"'s anatomy.

Claims

1. A method of making a knee implant system for repairing a knee joint of a patient, comprising:

a. determining a three-dimensional shape of at least a portion of an articular surface of the knee joint of the patient from electronic image data of the knee joint of the patient;

b. altering a first blank implant to form a femoral implant, wherein at least a portion of an articulating surface of the femoral implant conforms to the three-dimensional shape, wherein the femoral implant further includes one or more femoral standard features;

c. altering a second blank implant to form a tibial implant, wherein at least a portion of an articulating surface of the tibial implant complements a corresponding portion of the articulating surface of the femoral implant, wherein the tibial implant includes one or more tibial standard features.

2. The method of claim 1, wherein the corresponding portion of the articulating surface of the femoral implant conforms to the three-dimensional shape.

3. The method of claim 1, wherein the corresponding portion of the articulating surface of the femoral implant includes the one or more femoral standard features.

4. The method of claim 1, wherein the one or more femoral standard features includes a standard intercondylar distance.

5. The method of claim 4, wherein the one or more tibial standard features includes a feature configured based on the standard intercondylar distance.

6. The method of claim 1, wherein the one or more femoral standard features includes a standard anchoring mechanism for the femoral implant.

7. The method of claim 1, wherein altering a first or second blank implant includes subtracting and/or adding material to one or more portions of the first or second blank implant.