Apparatus and method for fabricating a customized patient-specific orthopaedic instrument

• US 10,828,046 B2
• Filed: 07/11/2018
• Issued: 11/10/2020
• Est. Priority Date: 09/30/2007
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Rose, Bryan, Roose, Jeffrey R., Aram, Luke J., Sokolov, Dimitri
• Primary Examiner(s): Yang, Andrew
• Application Number:
  US16/032,871
• Publication Number:
  US 20180317937A1
• Time in Patent Office: 853 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 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 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: Y10T 409/30084 with regulation of operation by templet, card, or other replaceable information supply

Abstract

A number of orthopaedic surgical instruments are also disclosed. A method, apparatus, and system for fabricating such instruments are also disclosed.

Claims

1. A method of manufacturing a customized patient specific orthopaedic surgical instrument, the method comprising:

obtaining a plurality of two-dimensional X-ray images of one or more bones,

generating a digital bone model of the one or more bones based solely on the two-dimensional X-ray images,

planning the customized patient specific orthopaedic surgical instrument, and

producing the customized patient specific orthopaedic surgical instrument, the customized patient specific orthopaedic surgical instrument including one or more anchor points adapted to engage a surface of the one or more bones,

wherein planning the customized patient specific orthopaedic surgical instrument includes determining locations for the one or more anchor points on the customized patient specific orthopaedic surgical instrument.

2. The method of claim 1, wherein the one or more anchor points include a customized patient-specific negative contour shaped to engage the surface of the one or more bones having a matching positive contour.

3. The method of claim 1, wherein the one or more anchor points include one or more drill guides, each drill guide being sized to receive to a surgical drill to establish one or more guide pin holes in the one or more bones.

4. The method of claim 3, wherein the each drill guide of the one or more drill guides is sized to receive a guide pin to secure the customized patient specific orthopaedic surgical instrument to the one or more bones.

5. The method of claim 1, wherein the customized patient specific orthopaedic surgical instrument is a cutting guide block.

6. The method of claim 1, wherein planning the customized patient specific orthopaedic surgical instrument includes determining locations for one or more drill guides in the customized patient specific orthopaedic surgical instrument to establish one or more guide pin holes in the one or more bones, and producing the customized patient specific orthopaedic surgical instrument includes producing the customized patient specific orthopaedic surgical instrument having one or more drill guides thereon.