Patient-specific instrumentation for implant revision surgery

• US 10,582,969 B2
• Filed: 07/08/2016
• Issued: 03/10/2020
• Est. Priority Date: 07/08/2015
• Status: Active Grant

• Current Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Couture, Pierre, Merette, Jean-Sebastien
• Primary Examiner(s): Lawson, Matthew J
• Application Number:
  US15/205,777
• Publication Number:
  US 20170007331A1
• Time in Patent Office: 1,341 Days
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 17/1778 for the shoulder
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61B 2034/102 Modelling of surgical devices, implants or prosthesis
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61F 2/461 of knees
• CPC Class Codes: A61F 2002/4687 Mechanical guides for implantation instruments

Abstract

A method for creating a model of a patient-specific instrumentation jig for implant revision includes obtaining an image of part of a patient bone and of an implanted implant on the bone. A reference anchor surface(s) is identified on the bone from the image, to receive a guide reference. An implant abutment surface is determined on the implanted implant. A virtual reference jig model is generated using the identified reference anchor surface and the determined implant abutment surface, and has a contact surface corresponding to the determined implant abutment surface for complementary connection with the determined implant abutment surface, a guide interfacing portion to guide a planting of the guide reference in the reference anchor surface, and a patient-specific geometry between the contact surface and the guide interfacing portion, to position and/or orient the guide interfacing portion relative to the reference anchor surface.

Claims

1. A method for creating at least one model of a patient-specific instrumentation jig for implant revision using a processing system, comprising:

obtaining at least one image of at least part of a bone requiring implant revision and of an implanted implant on the bone, the at least one image being patient specific;

identifying at least one reference anchor surface on the bone from the at least one image of the bone, the reference anchor surface configured to receive at least one guide reference;

determining an implant abutment surface on the implanted implant; and

generating and outputting a virtual reference jig model using at least the identified reference anchor surface and the determined implant abutment surface, the reference jig model comprising at least one contact surface corresponding to the determined implant abutment surface for complementary connection with the determined implant abutment surface, at least one guide interfacing portion configured to guide a planting of the at least one guide reference in the reference anchor surface, and a body interconnecting the at least one contact surface and the at least one guide interfacing portion, the body having a patient-specific geometry between the at least one contact surface and the at least one guide interfacing portion, so as to position and/or orient the at least one guide interfacing portion relative to the at least one reference anchor surface, for subsequently planting the at least one guide reference in the at least one reference anchor surface as identified when the at least one contact surface is complementarily connected with the determined implant abutment surface; and

generating a revision jig model using at least the position and orientation of the at least one guide reference and a virtual model of a replacement implant, the jig model comprising at least another guide interfacing portion for engagement with the at least one guide reference, at least one tool interface portion positioned and/or oriented relative to the guide reference and at least one patient-specific geometry between the guide interfacing portion and the at least one tool interface portion, the at least one tool interface portion adapted to be interfaced with a tool altering the bone to perform cuts for subsequently installing the replacement implant.

2. The method according to claim 1, wherein generating the revision jig model comprises creating a bone contact surface for contact with the reference anchor surface.

3. The method according to claim 1, wherein generating and outputting the reference jig model comprises using a virtual model of a replacement implant and planned position thereof, and a virtual model of a stock revision jig to create the patient-specific geometry of the reference jig model.

4. The method according to claim 1, wherein obtaining the at least one image comprises obtaining radiographic images only.

5. The method according to claim 1, wherein generating the reference jig model comprises obtaining a virtual 3D model of the implanted implant for creating the at least one contact surface.

6. The method according to claim 5, wherein creating the at least one contact surface comprises creating a negative surface of a portion of the implant abutment surface.

7. The method according to claim 1, wherein the at least one guide reference is a pair of guide pins, and wherein generating the reference jig model comprises defining pin guides in the at least one guide interfacing portion.

8. The method according to claim 1, wherein identifying the at least one reference anchor surface on the bone comprises identifying one of the medial epiphyseal bone and the anterior cortex from a femur.

9. The method according to claim 1, wherein identifying the at least one reference anchor surface on the bone comprises identifying one of the medial aspect, the lateral aspect and the superior tubercle from a tibia.

10. The method according to claim 1, wherein creating the generating and outputting a virtual reference jig model comprises generating and outputting at least one of an additive printing instructions model and a numerical control machining instructions model.

11. The method according to claim 1, further comprising using the virtual reference jig model and/or the revision jig model to fabricate the at least one patient-specific instrumentation jig.