Multi-point fit for patient specific guide

• US 9,700,325 B2
• Filed: 01/12/2017
• Issued: 07/11/2017
• Est. Priority Date: 03/12/2013
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Schoenefeld, Ryan John
• Primary Examiner(s): BOLES, SAMEH RAAFAT
• Application Number:
  US15/404,513
• Publication Number:
  US 20170119401A1
• Time in Patent Office: 180 Days
• Field of Search: None
• CPC Class Codes: A61B 17/15 Guides therefor arrangements for guiding straight saw blades in general B23D51/025
• CPC Class Codes: A61B 17/155 Cutting femur
• 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: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations

Abstract

A bone preparation system including a guide body and a plurality of bone locators. The guide body is configured to mate with a patient-specific module having a patient-specific module surface customized based on image data of a specific patient to correspond to the patient'"'"'s specific bone geometry. The plurality of bone locators are coupled to the guide body and positioned by the patient-specific module surface to define a patient-specific bone engaging surface of the guide corresponding to the patient'"'"'s specific bone geometry.

Claims

1. A method of customizing a bone preparation guide to correspond to a specific bone geometry of each one of a plurality of different patients, the method comprising:

analyzing a first patient'"'"'s specific bone geometry;

developing a first pre-operative plan based on the first patient'"'"'s specific bone geometry, a first patient-specific surface of a first patient-specific guide insert is designed based on the first pre-operative plan;

coupling the first patient-specific guide insert to a guide body, the guide body including a plurality of bone locators connected thereto that are configured to be positioned by the first patient-specific surface of the guide insert to define a first patient-specific bone engaging surface of the guide corresponding to the first patient'"'"'s specific bone geometry;

positioning the guide body against the first patient'"'"'s bone at a predetermined location corresponding to the first patient-specific bone engaging surface defined by the plurality of bone locators as positioned by the first guide insert; and

guiding at least one of a first cutting instrument or a first guide to the first patient'"'"'s bone using the guide.

2. The method of claim 1, further comprising:

analyzing a second patient'"'"'s specific bone geometry;

developing a second pre-operative plan based on the second patient'"'"'s specific bone geometry, a second patient-specific surface of a second patient-specific guide insert is designed based on the second pre-operative plan;

coupling the second patient-specific guide insert to the guide body, the guide body including a plurality of bone locators connected thereto that are configured to be positioned by the second patient-specific surface of the guide insert to define a second patient-specific bone engaging surface of the guide corresponding to the second patient'"'"'s specific bone geometry;

positioning the guide body against the second patient'"'"'s bone at a predetermined location corresponding to the second patient-specific bone engaging surface defined by the plurality of bone locators as positioned by the second guide insert; and

guiding at least one of a second cutting instrument or a second guide to the second patient'"'"'s bone using the guide.

3. The method of claim 1, further comprising guiding at least one of the first cutting instrument or the first guide through bores defined in the first patient-specific guide insert.

4. The method of claim 1, further comprising coupling the first patient-specific guide insert to the guide body by inserting the first patient-specific guide insert into a compartment defined by the guide body.

5. The method of claim 1, further comprising coupling a second patient-specific guide insert to the guide body after the first patient-specific guide insert has been removed, a second patient-specific surface of the second patient-specific guide insert is based on a second patient'"'"'s specific bone geometry.

6. The method of claim 1, further comprising moving the bone locators into contact with the first patient-specific surface of the first patient-specific guide insert by placing the bone locators into contact with the first patient'"'"'s bone.

7. A method of configuring a patient-specific bone preparation guide, the method comprising:

grasping a patient-specific insert having a patient-specific surface that is a three-dimensional inverse of a bone surface to be cut;

inserting the patient-specific insert into a compartment of a guide body so that the patient-specific surface is opposite a plurality of movable bone locators extending into the guide body;

positioning the moveable bone locators in the guide body opposite the bone surface to be cut;

translating a plurality of the movable bone locators through the guide body to contact the patient-specific surface; and

adjusting the moveable bone locators so that the moveable bone locators extend between anatomic features of the bone surface and portions of the three-dimensional inverse of the patient-specific surface that correspond to the anatomic features.

8. The method of claim 7, wherein inserting the patient-specific insert into the compartment of the guide body comprises sliding the insert into a slot in the guide body.

9. The method of claim 8, wherein the plurality of bone locators extend through a bone-facing surface of the guide body into the compartment, the bone-facing surface extending parallel to the slot such that the patient-specific surface faces the bone-facing surface.

10. The method of claim 7, wherein each of the movable bone locators comprises a distal tip extending out of the guide body and a proximal end disposed within the compartment, and translating the plurality of movable bone locators through the guide body to contact the patient-specific surface comprises forming a patient-specific bone-engaging surface with the distal tips.

11. The method of claim 10, further comprising:

viewing the distal tips of the movable bone locators;

evaluating if the distal tips are engaging the bone surface to be cut; and

repositioning the patient-specific bone preparation guide until all of the distal tips contact bone.

12. The method of claim 7, further comprising guiding a guide rod through a first guide bore defined in the guide body.

13. The method of claim 12, further comprising guiding the guide rod through a second guide bore defined in the first patient-specific insert.

14. The method of claim 12, further comprising guiding a cutting instrument through a cutting bore defined in the guide body.

15. The method of claim 12, further comprising:

removing the guide body from the guide rod;

coupling a generic cutting guide to the guide rod; and

guiding a cutting instrument through the generic cutting guide.

16. The method of claim 7, further comprising overcoming spring bias to translate the plurality of the movable bone locators.

17. The method of claim 7, further comprising:

inserting a second patient-specific insert into a second compartment of the guide body; and

translating a second plurality of movable bone locators through the guide body to contact the second patient-specific insert.

18. A method of manufacturing a patient-specific bone preparation guide, the method comprising:

obtaining a three-dimensional image of a bone surface to be cut;

fabricating an insert having dimensions to fit within a compartment of a guide housing having a plurality of moveable bone locators; and

shaping a surface of the insert to have a patient-specific surface having facets that are an inverse of the surface to be cut.

19. The method of claim 18, further comprising machining the insert to form the facets of the patient-specific surface.

20. The method of claim 18, further comprising inserting the insert into the compartment of the guide housing.