Method for forming a patient specific surgical guide mount

• US 9,883,870 B2
• Filed: 04/20/2015
• Issued: 02/06/2018
• Est. Priority Date: 02/24/2009
• Status: Active Grant

• Current Assignee: MicroPort Orthopedics Holdings, Inc. (MicroPort Scientific Corp.)
• Original Assignee: MicroPort Orthopedics Holdings, Inc. (MicroPort Scientific Corp.)
• Inventors: Carroll, Michael, Obert, Richard, Stemniski, Paul
• Primary Examiner(s): HANNA, SAMUEL SALEEB
• Application Number:
  US14/691,033
• Publication Number:
  US 20150223822A1
• Time in Patent Office: 1,023 Days
• CPC Class Codes: A61B 17/151 for corrective osteotomy
• CPC Class Codes: A61B 17/154 for preparing bone for knee prosthesis
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 2017/0023 disposable
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2034/104 Modelling the effect of the tool, e.g. the effect of an implanted prosthesis or for predicting the effect of ablation or burring
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49863 with prestressing of part

Abstract

A method includes mapping a contoured surface of at least one bone onto a digital model of a resection guide locator using a processor to create a digital model of a customized resection guide locator and manufacturing the customized resection guide locator. The customized resection guide locator includes a complementary surface of the at least one bone and a wall having a shape that is complementary to an outer profile of a resection guide and defining a pocket. A first elongate slot and at least one first hole are positioned within the pocket such that the first elongate slot aligns with a second elongate slot defined by the resection guide and the at least one first hole aligns with at least one second hole defined by the resection guide when the resection guide is received within the pocket of the customized resection guide locator.

Claims

1. A method, comprising:

mapping a contoured surface of at least one bone onto a digital model of a resection guide locator using a processor to create a digital model of a customized resection guide locator; and

manufacturing the customized resection guide locator such that the customized resection guide locator includes;

a complementary surface of the at least one bone,

a wall having a shape that is complementary to an outer profile of a resection guide such that a pocket is defined that is sized and configured to receive the resection guide therein,

wherein a first elongate slot and at least one first hole are defined within the pocket, the first elongate slot and the at least one first hole are positioned within the pocket such that the first elongate slot aligns with a second elongate slot defined by the resection guide and the at least one first hole aligns with at least one second hole defined by the resection guide when the resection guide is received within the pocket of the customized resection guide locator.

2. The method of claim 1, further comprising

acquiring an anatomically accurate image of the at least one bone by scanning the at least one bone of a patient in two scans, wherein between the scans the patient is moved in order to reposition a coil of an imaging apparatus to cover a most proximal or a most distal region of the at least one bone;

converting the anatomically accurate image to a digital model of the at least one bone.

3. The method of claim 2, wherein mapping the contoured surface of at least one bone onto a digital model of a resection guide locator includes applying the digital model of the resection guide locator to a surface of the digital model of the at least one bone.

4. The method of claim 1, wherein the resection guide locator is manufactured using stereo lithography.

5. The method of claim 1, wherein the resection guide locator is manufactured using selective laser sintering.

6. The method of claim 1, wherein the at least one first hole does not intersect the first elongate slot.

7. A method, comprising:

mapping a contoured surface of at least one bone onto a digital model of a resection guide locator using a processor to create a digital model of a customized resection guide locator; and

manufacturing the customized resection guide locator using stereo lithography such that the customized resection guide locator includes;

a complementary surface of the at least one bone,

a wall having a shape that is complementary to an outer profile of a resection guide such that a pocket is defined that is sized and configured to receive the resection guide therein,

wherein a first elongate slot and a first pair of holes are defined within the pocket, the first elongate slot and the first pair of holes are positioned within the pocket such that the first elongate slot aligns with a second elongate slot defined by the resection guide and the first pair of holes align with a second pair of holes defined by the resection guide when the resection guide is received within the pocket of the customized resection guide locator.

8. The method of claim 7, further comprising

acquiring an anatomically accurate image of the at least one bone by scanning the at least one bone of a patient in two scans, wherein between the scans the patient is moved in order to reposition a coil of an imaging apparatus to cover a most proximal or a most distal region of the at least one bone;

converting the anatomically accurate image to a digital model of the at least one bone.

9. The method of claim 8, wherein mapping the contoured surface of at least one bone onto a digital model of a resection guide locator includes applying the digital model of the resection guide locator to a surface of the digital model of the at least one bone.

10. The method of claim 8, wherein scanning the at least one bone in two scans includes applying a pulse sequence to the coil of the imaging apparatus of at least one of a FATSEP 3D RSSG and a 2D T1 FSE.

11. The method of claim 8, wherein scanning the bone in two scans includes performing at least one of the two scans with an acquisition time of at least one of 5:

46 (min;

sec) and 15;

37 (min;

sec).

12. The method of claim 7, wherein the first pair of holes do not intersect the first elongate slot.

13. The method of claim 7, wherein the pocket of the customized resection guide locator is sized to receive the resection guide with a press fit.

14. A method, comprising:

mapping a contoured surface of at least one bone onto a digital model of a resection guide locator using a processor to create a digital model of a customized resection guide locator; and

manufacturing the customized resection guide locator using laser sintering such that the customized resection guide locator includes;

a complementary surface of the at least one bone,

a wall having a shape that is complementary to an outer profile of a resection guide such that a pocket is defined that is sized and configured to receive the resection guide therein,

wherein a first elongate slot and a first pair of holes are defined within the pocket, the elongate slot and the first pair of holes are positioned within the pocket such that the first elongate slot aligns with a second elongate slot defined by the resection guide and the first pair of holes align with a second pair of holes defined by the resection guide when the resection guide is received within the pocket of the customized resection guide locator.

15. The method of claim 14, further comprising

acquiring an anatomically accurate image of the at least one bone by scanning the at least one bone of a patient in two scans, wherein between the scans the patient is moved in order to reposition a coil of an imaging apparatus to cover a most proximal or a most distal region of the at least one bone;

converting the anatomically accurate image to a digital model of the at least one bone.

16. The method of claim 15, wherein mapping the contoured surface of at least one bone onto a digital model of a resection guide locator includes applying the digital model of the resection guide locator to a surface of the digital model of the at least one bone.

17. The method of claim 15, wherein scanning the at least one bone in two scans includes applying a pulse sequence to the coil of the imaging apparatus of at least one of a FATSEP 3D RSSG and a 2D T1 FSE.

18. The method of claim 15, wherein scanning the bone in two scans includes performing at least one of the two scans with an acquisition time of at least one of 5:

46 (min;

sec) and 15;

37 (min;

sec).

19. The method of claim 14, wherein the first pair of holes do not intersect the first elongate slot.

20. The method of claim 14, wherein the pocket of the customized resection guide locator is sized to receive the resection guide with a press fit.