Implant device and method for manufacture

• US 9,700,971 B2
• Filed: 12/19/2013
• Issued: 07/11/2017
• Est. Priority Date: 05/25/2001
• Status: Expired due to Fees

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Lang, Philipp
• Primary Examiner(s): Philogene, Pedro
• Application Number:
  US14/134,064
• Publication Number:
  US 20140109384A1
• Time in Patent Office: 1,300 Days
• Field of Search: 128898, 623901, 623 1311, 623 1811, 623 1911, 623 2014, 623 1716, 623 2358, 623 2029, 623908, 264222, 600594, 600589, 700 95- 98, 700118, 703 11, 29557
• 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: B23P 19/04 : for assembling or disassembling parts
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: G06F 30/00 : Computer-aided design [CAD]
• CPC Class Codes: Y10T 29/49995 : Shaping one-piece blank by removing material

Abstract

A knee implant includes a femoral component having first and second femoral component surfaces. The first femoral component surface is for securing to a surgically prepared compartment of a distal end of a femur. The second femoral component surface is configured to replicate the femoral condyle. The knee implant further includes a tibial component having first and second tibial component surfaces. The first tibial component surface is for contacting a proximal surface of the tibia that is substantially uncut subchondral bone. At least a portion of the first tibial component surface is a mirror image of the proximal tibial surface. The second tibial component surface articulates with the second femoral component surface.

Claims

1. A method of manufacturing an implant for repairing a knee joint of a patient, wherein the implant includes a joint-facing surface and a bone-facing surface, the method comprising:

a. deriving a three-dimensional shape of the knee joint of the patient from image data of the knee joint of the patient, wherein the image data include information about a shape, geometry or articular surface of a femoral condyle of the knee joint of the patient,

b. providing a blank with at least one dimension larger than a corresponding dimension of the femoral condyle of the knee joint of the patient, wherein the blank is selected from a library of implants of various sizes and/or shapes; and

c. altering the blank to obtain a desired shape of the joint-facing surface of the implant, wherein the desired shape replicates the femoral condyle of the knee joint of the patient in the corresponding dimension.

2. The method of claim 1, wherein the implant includes a medial condylar portion and a lateral condylar portion.

3. The method of claim 2, wherein the implant further includes a tibial component that provides both medial and lateral tibial plateaus.

4. The method of claim 3, including configuring the tibial component to leave tibial spines of the knee joint of the patient intact.

5. The method of claim 3, including configuring the tibial component not to leave tibial spines of the knee joint of the patient intact.

6. The method of claim 2, wherein the tibial component includes a first portion that provides a medial tibial plateau and a second portion that provides a lateral tibial plateau, wherein the first and second portions are separately formed.

7. The method of claim 1, including entering the three-dimensional shape into a CAD/CAM system.

8. The method of claim 7, wherein the CAD/CAM system is used to form the desired shape of the implant.