Patient-specific implants with improved osseointegration

• US 9,707,058 B2
• Filed: 07/10/2009
• Issued: 07/18/2017
• Est. Priority Date: 07/10/2009
• Status: Active Grant

• Current Assignee: Zimmer Dental Inc. (Zimvie Incorporated)
• Original Assignee: Zimmer Dental Inc. (Zimvie Incorporated)
• Inventors: Collins, Michael, Cahill, Sean, Bassett, Jeffrey A.
• Primary Examiner(s): Rodriguez, Cris L
• Assistant Examiner(s): APONTE, MIRAYDA ARLENE
• Application Number:
  US12/501,163
• Publication Number:
  US 20110008754A1
• Time in Patent Office: 2,930 Days
• Field of Search: 433174, 433175, 433173, 433172, 4332011, 2989611
• CPC Class Codes: A61C 8/0012 characterised by the material or composition, e.g. ceramics, surface layer, metal alloy use of specific materials A61K6/00
• CPC Class Codes: A61C 8/0013 with a surface layer, coating
• CPC Class Codes: A61F 2/2803 for mandibular reconstruction temporo-mandibular joints A61F2/3099; bone plates for the jaw A61B17/8071
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• 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 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30929 having at least two superposed coatings
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: A61F 2250/0023 differing in porosity
• CPC Class Codes: A61F 2310/00161 Carbon; Graphite
• CPC Class Codes: A61F 2310/00544 Coating made of tantalum or Ta-based alloys
• CPC Class Codes: A61L 2430/02 for reconstruction of bones; weight-bearing implants
• CPC Class Codes: A61L 27/08 Carbon ; Graphite
• CPC Class Codes: A61L 27/30 Inorganic materials
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49568 Orthodontic device making

Abstract

A patient-specific bone implant has a porous body with a core material covered with tantalum. It is made with unique outer dimensions selected to match a specific patient.

Claims

1. A patient-specific bone implant configured for a bone defect of a patient, the patient-specific bone implant being formed by:

determining anatomical information of an area of the patient that includes the bone defect, including obtaining the dimensions of the bone defect;

generating a digital model of at least the dimensions of the bone defect based on the anatomical information;

planning a three dimensional implant model using virtual structures generated in the digital model, the three dimensional implant model including mathematical representations of a surface of the bone defect;

providing a block of porous metal material including a core material at least partially coated with a biocompatible metal material;

shaping the block of porous metal material based on the mathematical representations of the bone defect into the patient specific-bone implant, wherein a body of the patient-specific bone implant has an outer surface sized and shaped to match the dimensions of the bone defect based on the mathematical representations of the bone defect surface, wherein at least a portion of the body has an irregular shape to match the surface of the bone defect, and wherein at least a portion of the outer surface of the body is porous such that the outer surface includes void space when the patient specific bone implant is implanted in a mouth of the patient;

wherein the patient specific-bone implant comprises;

a body portion comprising;

a conical anchor portion at an apical end of the implant;

an irregular shaped portion connected to the conical anchor portion, the irregular shaped portion including the irregular shape and shaped to accommodate one or more of a nerve location, sinus cavity or tooth root of the area of the patient; and

a bore extending into only the irregular shaped portion; and

a collar portion threaded into the bore at a coronal end of the body portion the collar portion having a prosthetic interface with a coronal cavity;

wherein the block of porous metal material includes a gradation of pore size such that pores are larger on an apical end and smaller on a coronal end.

2. The implant of claim 1 wherein the patient-specific bone implant is a root-form implant that corresponds to the root of a single tooth and supports at least one prosthesis.

3. The implant of claim 1 wherein the patient-specific bone implant supports more than one prosthesis.

4. The patient-specific bone implant of claim 1 wherein the implant replaces multiple tooth root sockets.

5. The patient-specific bone implant of claim 1 wherein the implant extends apically of the alveolar margin.

6. The implant of claim 1 wherein the digital model includes information on the nerve locations, sinus cavities and tooth roots.

7. The implant of claim 1 wherein the digital model includes information on bone density.

8. The implant of claim 1 wherein the collar portion is fabricated from a material other than the porous material.

9. The implant of claim 1 wherein the coronal cavity has a hexagon shape.

10. The implant of claim 1 wherein the block of porous material is shaped into the shape of the bone defect prior to implantation.

11. The implant of claim 1 wherein the core material is carbon foam, and the biocompatible metal material is tantalum.

12. A patient-specific bone implant configured for a bone defect of a patient, the patient-specific bone implant being formed by:

determining anatomical information of an area of the patient that includes the bone defect, including obtaining dimensions of the bone defect;

generating a digital model of an area of the patient including the bone defect, based on the anatomical information;

planning a three dimensional implant model using virtual structures generated in the digital model;

providing a block of porous material including a core material at least partially coated with a biocompatible metal; and

shaping the block of porous material into the patient-specific bone implant based on the three dimensional implant model, wherein the block of porous material includes a gradation of pore size such that pores are larger on an apical end and smaller on a coronal end, wherein a body of the patient-specific bone implant has an outer surface sized and shaped to match the dimensions of the bone defect in the digital model, and the core material of the porous material is a carbon foam at least partially coated with the biocompatible metal before or after shaping the block of porous material, and wherein at least a portion of the outer surface of the body is porous such that the outer surface includes void space when the patient specific bone implant is implanted in a mouth of the patient.

13. The patient-specific bone implant of claim 12 wherein the biocompatible metal is tantalum.

14. The patient-specific bone implant of claim 12 wherein the implant is a root-form implant that corresponds to the root of a single tooth and supports at least one prosthesis, the root-form implant comprising:

a conical anchor portion at an apical end of the block of porous material;

a prosthetic interface portion coupled to a coronal end of the block of porous material; and

a body portion comprising the coronal end of the block of porous material, the body portion having an irregular shape to accommodate one or more of a nerve location, sinus cavity or tooth root of the area of the patient.

15. The implant of claim 14 wherein the prosthetic interface portion is fabricated from a material other than the porous material.

16. The patient-specific bone implant of claim 12 wherein the implant supports more than one prosthesis.

17. The implant of claim 12 wherein the patient specific bone implant has an irregular shape to match the surface of the bone defect.