Patient-specific glenoid guide and implants

• US 9,554,910 B2
• Filed: 10/17/2012
• Issued: 01/31/2017
• Est. Priority Date: 10/27/2011
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Taylor, Robert, Vanasse, Thomas M., Kehres, Clinton E.
• Primary Examiner(s): Craig, Dwin M
• Application Number:
  US13/653,886
• Publication Number:
  US 20130110470A1
• Time in Patent Office: 1,567 Days
• Field of Search: 703/2
• 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 2/40 for shoulders
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: B29C 33/3835 Designing moulds, e.g. using CAD-CAM
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses
• CPC Class Codes: B29L 2031/757 Moulds, cores, dies
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F04C 2270/041 Controlled or regulated

Abstract

A method is disclosed for repairing a defect in an anatomical feature, the defect having a surface that defines a volume. The method includes receiving imaging data obtained using a medical imaging technique. The imaging data represents the anatomical feature. In one example, the method further includes creating a three-dimensional (3D) model of a mold for an implant based on the imaging data. The mold includes a cavity that replicates the volume of the defect. In another example, the method further includes creating a 3D model of an implant based on the imaging data. The implant is configured to fill the volume of the defect. In various implementations, the mold, the implant, and/or a replica of the implant are formed based on the 3D model of the mold or the 3D model of the implant. Guides and implants corresponding to the method are also disclosed.

Claims

1. A method for forming a mold for use in repairing a defect in a bone, the defect having a surface that defines a volume within the bone, the method comprising:

receiving imaging data obtained using a medical imaging technique, the imaging data representing the bone and a defect in the bone, the defect including a cavity in the bone;

creating a three-dimensional (3D) model of a mold for an implant based on the imaging data, the mold including a cavity that replicates the volume and shape of the cavity of the defect, the mold further including a first portion having a first surface that matches the surface of the defect defining the volume, and a second portion having a second surface for defining a portion of an articular surface at the location of the defect;

forming the mold based on the 3D model; and

creating a 3D model of a guide based on the imaging data, the guide being configured to position a cutting tool relative to the bone as the cutting tool is used to create a void in the bone, the guide includes a nesting surface configured to engage the surface of the defect defining the volume to position the guide relative to the bone.

2. The method of claim 1 wherein the anatomical feature bone includes at least one of a glenoid fossa and a humerus.

3. The method of claim 1 wherein the medical imaging technique includes at least one of a computed tomography (CT scan), a magnetic resonance imaging (MRI), and an x-ray.

4. The method of claim 1 further comprising forming the implant using the mold.

5. The method of claim 1 further comprising designing the mold such that the first portion is part of a first piece and the second portion is part of a second piece that is separate from the first piece.

6. The method of claim 1 further comprising designing the second surface to cooperate with an outer surface of the bone surrounding the defect to form a continuous surface.

7. The method of claim 1 wherein the nesting surface is configured to engage the surface of the defect defining the volume such that there is only one way for the guide to fit onto the bone.

8. A method for forming an implant for use in repairing a defect in a bone, the defect having a surface that defines a volume within the bone, the method comprising:

receiving imaging data obtained using a medical imaging technique, the imaging data representing the bone and a defect in the bone, the defect including a cavity in the bone;

creating a three-dimensional (3D) model of an implant based on the imaging data, the implant being configured to fill the volume of the cavity of the defect, the implant including a first surface that conforms to the shape of the defect surface that defines the volume of the cavity of the defect and a second surface that forms a portion of an articular surface at the location of the defect; and

creating a 3D model of a guide based on the imaging data, the guide being configured to position a cutting tool relative to the bone as the cutting tool is used to create a void in the bone, the guide includes a nesting surface configured to engage the surface of the defect defining the volume to position the guide relative to the bone.

9. The method of claim 8 further comprising providing the 3D model to a medical professional for use in forming the implant.

10. The method of claim 8 further comprising forming a replica of the implant based on the 3D model.

11. The method of claim 10 further comprising providing the replica of the implant to a medical professional for use in forming the implant.

12. The method of claim 8 further comprising forming the implant based on the 3D model.

13. The method of claim 8 wherein the nesting surface is configured to engage the surface of the defect defining the volume such that there is only one way for the guide to fit onto the bone.