Method of generating a patient-specific bone shell

• US 9,937,046 B2
• Filed: 10/03/2014
• Issued: 04/10/2018
• Est. Priority Date: 02/25/2009
• Status: Active Grant

• Current Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Mahfouz, Mohamed Rashwan
• Primary Examiner(s): WOLDEMARIAM, AKLILU K
• Application Number:
  US14/505,916
• Publication Number:
  US 20150120031A1
• Time in Patent Office: 1,285 Days
• Field of Search: 382128, 382131, 382132, 382151, 382154, 382203, 600409, 600426, 600443, 600300, 600411, 600425, 600416, 600637, 600439
• CPC Class Codes: A61B 2034/102 Modelling of surgical devices, implants or prosthesis
• 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: A61B 8/4245 involving determining the position of the probe, e.g. with respect to an external reference frame or to the patient
• 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 2/3601 for replacing only the epiphyseal or metaphyseal parts of the femur, e.g. endoprosthetic femoral heads or necks directly fixed to the natural femur by internal fixation devices non-prosthetic internal fixation devices for the femoral head or neck A61B17/74
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/4003 Replacing only the epiphyseal or metaphyseal parts of the humerus, i.e. endoprosthesis not comprising an entire humeral shaft replacing only the epiphyseal or metaphyseal parts of the femur A61F2/3601
• CPC Class Codes: A61F 2002/30943 using mathematical models
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/3863 Condyles fitted on an anchored base
• CPC Class Codes: A61F 2002/3895 unicompartimental
• CPC Class Codes: G06F 17/18 for evaluating statistical data , e.g. average values, frequency distributions, probability functions, regression analysis forecasting specially adapted for a specific administrative, business or logistic context G06Q10/04
• CPC Class Codes: G06F 18/00 Pattern recognition
• CPC Class Codes: G06T 19/00 Manipulating 3D models or images for computer graphics
• CPC Class Codes: G06T 2210/41 Medical
• CPC Class Codes: G16H 50/50 for simulation or modelling of medical disorders
• CPC Class Codes: G16Z 99/00 : Subject matter not provided for in other main groups of this subclass

Abstract

The exemplary embodiments of the present disclosure are described and illustrated below to encompass methods and devices for designing patient specific prosthetic cutting jigs and, more specifically, to devices and methods for segmenting bone of the knee and the resulting cutting guides themselves. Moreover, the present disclosure relates to systems and methods for manufacturing customized surgical devices, more specifically, the present disclosure relates to automated systems and methods of arthroplasty cutting guides, systems and methods for image segmentation in generating computer models of knee joint.

Claims

1. A reconstruction system for generating a patient-specific bone shell representative of at least a portion of a patient'"'"'s bone in its current state comprising:

a recognition module configured for receiving a plurality of 2D images of a portion of a patient'"'"'s anatomy, the recognition module recognizing from the plurality of 2D image slices at least a bone segment comprising an enclosed boundary corresponding to an exterior of the patient'"'"'s bone;

a construction module to produce and output a 3D image bone shell of at least the portion of the patient'"'"'s bone by associating the plurality of 2D images of the patient'"'"'s bone based on the recognition of the enclosed boundary of each bone segment, where the 3D image bone shell depicts a current state of the patient'"'"'s bone.

2. The reconstruction system of claim 1, wherein the plurality of 2D images are computed tomography images.

3. The reconstruction system of claim 1, wherein the 3D image bone shell is representative of at least one of a femur, a tibia, and a humerus.

4. The reconstruction system of claim 1, further comprising a generation module to generate a 3D image surgical jig to mate with said 3D image bone shell, where the 3D image surgical jig includes topographical features customized to the exterior features of the 3D image bone shell.

5. The reconstruction system of claim 4, wherein the generation module outputs an instruction file for fabricating a surgical jig having tangible topographical features of the 3D image surgical jig.

6. The reconstruction system of claim 1, wherein the recognition module recognizes an outline of cartilage appearing in at least one said 2D images, and further wherein the construction module produces a 3D image cartilage shell representing at least a portion of a patient'"'"'s cartilage using the plurality of 2D images of the patient'"'"'s anatomy based on the recognition of the outline of cartilage.

7. The reconstruction system of claim 6, wherein the recognition module recognizes the outline of cartilage appearing in at least one said 2D images by determining cartilage thickness using at least one of statistical shape atlases and Bayesian inversion probabilities.

8. The reconstruction system of claim 1, wherein the recognition module enables interactive intervention for at least one of contour adding, subtracting and painting.

9. The reconstruction system of claim 1, wherein each of the plurality of 2D images is orthogonal to an axis extending through the patient'"'"'s anatomy.

10. The reconstruction system according to claim 1, wherein the recognition module recognizes the enclosed boundary of each bone segment on the 2D images by using a template 3D image bone shell that is not patient specific.

11. The reconstruction system of claim 10, wherein the template 3D image bone shell that is not patient specific is obtained from a library of bone models.