Patient selectable knee arthroplasty devices

• US 8,545,569 B2
• Filed: 01/05/2004
• Issued: 10/01/2013
• Est. Priority Date: 05/25/2001
• Status: Expired due to Term

• Current Assignee: Conformis Incorporated
• Original Assignee: Conformis Incorporated
• Inventors: Fitz, Wolfgang, Lang, Philipp, Steines, Daniel, Tsougarakis, Konstantinos, Vargas-Voracek, Rene, Bouadi, Hacene, Snyder, Cecily Anne
• Primary Examiner(s): STEWART, JASON-DENNIS NEILKEN
• Application Number:
  US10/752,438
• Publication Number:
  US 20040204760A1
• Time in Patent Office: 3,557 Days
• Field of Search: 623/14.12, 623 2372- 2376, 623/20.35, 623/20.36, 623/20.14, 623/20.15
• US Class Current: 623/20.14
• CPC Class Codes: A61B 5/4504 Bones A61B5/4547 takes precedence
• CPC Class Codes: A61B 5/4514 Cartilage
• CPC Class Codes: A61B 5/4528 Joints A61B5/4533, A61B5/4538 take precedence
• CPC Class Codes: A61F 2/30756 Cartilage endoprostheses A61F2/3603 takes precedence
• 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 2/3859 Femoral components
• CPC Class Codes: A61F 2/3877 Patellae or trochleae
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: A61F 2002/4635 using minimally invasive surgery
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G06T 2207/30052 Implant; Prosthesis
• CPC Class Codes: G06T 7/0014 using an image reference approach

Abstract

Disclosed herein are methods and devices for repairing articular surfaces in a knee joint. The articular surface repairs are customizable or highly selectable for each patient and geared toward providing optimal fit and function. Kits are also provided to enable customized repairs to be performed.

Claims

1. An implant for implantation on a patient'"'"'s femur, the implant comprising:

(a) a condylar portion having (i) a condylar bone-facing implant surface configured to oppose at least a portion of a femoral condyle of the patient'"'"'s femur and (ii) a condylar articular implant surface configured to articulate with at least a portion of a tibial surface; and

(b) a trochlear portion having (i) a bone-facing implant surface configured to oppose at least a portion of a trochlea and (ii) an articular implant surface configured to articulate with at least a portion of a patellar surface, when the implant is implanted on the patient'"'"'s femur;

wherein the condylar portion and the trochlear portion are formed as a single component; and

wherein at least a portion of one of the bone-facing implant surfaces comprises a chamfer cut surface to abut a bone cut surface and wherein the condylar portion is configured to have at least portions of the patient'"'"'s femoral shape and include patient-specific shape information derived from electronic image data of the femoral condyle.

2. The implant of claim 1, wherein the implant is selected from a library of implants and further manipulated to match the patient'"'"'s femur.

3. The implant of claim 1, wherein the implant has only one condylar portion.

4. The implant of claim 1, wherein the condylar portion is a first condylar portion and the implant further comprises a second condylar portion, wherein the first and second condylar portions are disposed on opposite sides of the trochlear portion.

5. The implant of claim 1, wherein the bone-facing implant surface of the trochlear portion bone is configured to abut at least a portion of uncut trochlear bone upon implantation of the implant.

6. The implant of claim 1, wherein the bone-facing implant surface of the trochlear portion bone is configured to abut at least a portion of cut trochlear bone upon implantation of the implant.

7. The implant of claim 1, wherein the condylar portion is configured to have at least portions of the patient'"'"'s femoral cartilage shape.

8. The implant of claim 1, wherein the condylar portion is configured to have at least portions of the patient'"'"'s femoral subchondral bone shape.

9. The implant of claim 1, wherein at least a portion of the outer shape of the condylar portion of the implant is derived based on a tibial component shape.

10. The implant of claim 1, wherein at least a portion of the outer shape of the condylar portion of the implant is a reflection of the tibial shape of an implant component.

11. The implant of claim 1, wherein at least a portion of the outer shape of the condylar portion of the implant is derived based on a desired tibiofemoral contact area.

12. A method of making the implant of claim 1, including shaping the implant using a 3-dimensional representation of a cartilage surface of the patient'"'"'s femur.

13. A method of making the implant of claim 1, including shaping the implant using a 3-dimensional representation of a subchondral bone surface of the patient'"'"'s femur.

14. A method of making the implant of claim 1, including manufacturing the implant using at least one of a NURBS surface and a parametric surface of polygon.

15. A method of making the implant of claim 1, including manufacturing the implant using a shell generated with a rapid prototyping system.

16. An implant for implantation on a patient'"'"'s femur, the implant comprising:

(a) a condylar portion having (i) a condylar bone-facing implant surface configured to oppose at least a portion of a femoral condyle of the patient'"'"'s femur and (ii) a condylar articular implant surface configured to articulate with at least a portion of a tibial surface; and

(b) a trochlear portion having (i) a bone-facing implant surface configured to oppose at least a portion of a trochlea and (ii) an articular implant surface configured to articulate with at least a portion of a patellar surface, when the implant is implanted on the patient'"'"'s femur; and

wherein at least a portion of one of the bone-facing implant surfaces comprises chamfer cut surface to abut a bone cut surface and wherein the condylar portion is configured to match a corrected joint anatomy of the patient and include patient-specific shape information derived from electronic image data of the femoral condyle.

17. The implant of claim 16, wherein the corrected joint anatomy includes one or more bone cuts.

18. An implant for implantation on a patient'"'"'s femur, the implant comprising:

(a) a condylar portion having (i) a condylar bone-facing implant surface configured to oppose at least a portion of a femoral condyle of the patient'"'"'s femur and (ii) a condylar articular implant surface configured to articulate with at least a portion of a tibial surface; and

(b) a trochlear portion having (i) a bone-facing implant surface configured to oppose at least a portion of a trochlea and (ii) an articular implant surface configured to articulate with at least a portion of a patellar surface, when the implant is implanted on the patient'"'"'s femur; and

wherein at least a portion of one of the bone-facing implant surfaces comprises a chamfer cut surface to abut a bone cut surface and wherein the condylar portion is configured to have at least portions of the patient'"'"'s femoral shape and include patient-specific information derived from electronic image data of the femoral condyle,

wherein the implant is selected from a library of implants and further manipulated to match the patient'"'"'s femur.

19. The implant of claim 18, wherein the library includes implants of various sizes.

20. The implant of claim 18, wherein the library includes implants of various shapes.

21. The implant of claim 18, wherein the library includes implants of various thicknesses.

22. The implant of claim 18, wherein the implant selected from the library is shaped by mechanical abrasion.

23. The implant of claim 18, wherein the implant selected from the library is shaped by, at least in part, an automated process.

24. The implant of claim 18, wherein the implant selected from the library is shaped by, at least in part, a manual process.