Patient-specific numerically controlled instrument

• US 9,717,510 B2
• Filed: 05/05/2014
• Issued: 08/01/2017
• Est. Priority Date: 04/15/2011
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Smith, Aaron P.
• Primary Examiner(s): BATES, DAVID W
• Application Number:
  US14/269,362
• Publication Number:
  US 20140243833A1
• Time in Patent Office: 1,184 Days
• Field of Search: 606 87
• CPC Class Codes: A61B 17/1626 Control means; Display units
• CPC Class Codes: A61B 17/1668 for the upper femur A61B17/164 takes precedence
• CPC Class Codes: A61B 17/1684 for the shoulder
• CPC Class Codes: A61B 17/17 Guides or aligning means for drills , mills, pins or wires
• CPC Class Codes: A61B 17/1742 for the hip
• CPC Class Codes: A61B 17/175 for preparing the femur for hip prosthesis insertion
• CPC Class Codes: A61B 17/1778 for the shoulder
• CPC Class Codes: A61B 17/56 Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
• CPC Class Codes: A61B 2017/1602 Mills
• CPC Class Codes: A61B 2017/564 Methods for bone or joint treatment
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A method for preparing a bone of a joint of a patient includes mounting a patient-specific reference guide on a bone of a joint of a patient. A connecting portion of the reference guide is coupled to a miniaturized numerically controlled instrument having a housing including a controller, a processor and a tool driver. The patient-specific reference guide has a three-dimensional inner surface preoperatively configured to mirror and mate with a corresponding surface of a bone of a joint of a patient in only one position. The patient-specific reference guide is configured to automatically register the numerically controlled instrument to the patient'"'"'s bone portion intraoperatively. The cutting tool is guided by the controlled with signals from the processor along a patient-specific tool path determined during the preoperative plan for preparing a portion of the bone.

Claims

1. A method for preparing a bone of a joint of a patient comprising:

mounting a patient specific reference guide on a bone of a joint of a patient, the patient specific reference guide having a three-dimensional inner surface preoperatively configured to mate and closely nest to a corresponding surface of the bone only in one position, wherein mounting the patient specific reference guide on a bone of a joint of a patient includes mounting the reference guide on a femoral head surface of the patient, and wherein the reference guide is configured for mating with the femoral head surface of the patient;

coupling a housing of a numerically-controlled instrument to a connecting portion coupled to an outer surface of the reference guide;

automatically registering the numerically controlled instrument to the bone by coupling the housing to the reference guide and without intraoperative computer-aided navigation;

coupling a cutting tool to the housing;

guiding the cutting tool along a patient-specific tool path using the numerically-controlled instrument while the housing is mounted to the reference guide, the patient-specific tool path determined preoperatively and stored in the numerically-controlled instrument; and

preparing a portion of the bone using the cutting tool.

2. The method of claim 1, wherein preparing the portion of the bone includes removing a femoral acetabular impingement defect from a femoral neck of the bone.

3. A method for preparing a bone of a joint of a patient comprising:

mounting a patient specific reference guide on a bone of a joint of a patient, the patient specific reference guide having a three-dimensional inner surface preoperatively configured from preoperative scans of the bone of the joint to mirror and mate with a corresponding surface of the bone only in one position;

coupling a guide connector of a housing of a miniaturized numerically-controlled instrument to a connecting portion coupled to an outer surface of the reference guide, the housing including the guide connector, a controller, a processor and a tool driver;

automatically registering the numerically controlled instrument to the bone by coupling the housing to the reference guide;

converting by the processor a patient-specific tool path to signals for the controller, the patient-specific tool path determined preoperatively and stored in the numerically-controlled instrument;

removably coupling a cutting tool to the housing;

operating by the controller the tool driver from the signals; and

guiding the cutting tool along the patient-specific tool path using the numerically-controlled instrument while the housing is mounted to the reference guide.

4. The method of claim 3, further comprising:

removing a femoral acetabular impingement defect with the cutting tool.

5. The method of claim 3, further comprising:

removing a bony growth of a femoral neck with the cutting tool.

6. The method of claim 3, further comprising:

preparing an acetabular socket of the joint for receiving an acetabular cup with the cutting tool.

7. The method of claim 3, further comprising:

resurfacing a femoral head of the joint with the cutting tool.

8. The method of claim 3, further comprising:

resurfacing a humeral head of the joint with the cutting tool.

9. The method of claim 3, further comprising:

removing a defect of a femoral head of the joint with the cutting tool.

10. The method of claim 3, wherein the reference guide is an annular ring and wherein mounting the patient specific reference guide on a bone of a joint of a patient further includes mating the annular ring to an annular area around a rim of the acetabulum of the patient.

11. The method of claim 10, further comprising preparing the acetabulum of the patient for receiving an implant.

12. The method of claim 3, wherein mounting the patient specific reference guide on a bone of a joint of a patient includes mounting the reference guide on a femoral head surface of the patient, and wherein the reference guide is a shell-like structure configured for mating with the femoral head surface of the patient.

13. A method for preparing a bone of a joint of a patient comprising:

mounting a patient specific reference guide on a bone of a joint of a patient, the patient specific reference guide having a three-dimensional inner surface preoperatively configured from preoperative scans of the bone of the joint to mirror and mate with a corresponding surface of the bone only in one position, the reference guide including a connecting portion;

coupling a housing of a miniaturized numerically-controlled instrument to the connecting portion of the reference guide, the housing including a controller, a processor and a tool driver;

automatically registering the numerically controlled instrument to the bone by coupling the housing to the inner surface of the reference guide;

processing and converting a patient-specific tool path to signals for the controller, the patient-specific tool path determined preoperatively and stored in the numerically-controlled instrument;

removably coupling a cutting tool to the housing;

controlling the tool driver from the signals; and

guiding the cutting tool along the patient-specific tool path using the numerically-controlled instrument while the housing is mounted to the reference guide.

14. The method of claim 13, further comprising:

removing a femoral acetabular impingement defect with the cutting tool.

15. The method of claim 13, further comprising:

removing a bony growth of a femoral neck with the cutting tool.

16. A method for preparing a bone of a joint of a patient comprising:

mounting a patient specific reference guide on a bone of a joint of a patient, the patient specific reference guide having a three-dimensional inner surface preoperatively configured to mate and closely nest to a corresponding surface of the bone only in one position, wherein mounting the patient specific reference guide on a bone of a joint of a patient includes mounting the reference guide on an acetabulum of the patient;

coupling a housing of a numerically-controlled instrument to a connecting portion coupled to an outer surface of the reference guide;

automatically registering the numerically controlled instrument to the bone by coupling the housing to the reference guide and without intraoperative computer-aided navigation;

coupling a cutting tool to the housing;

guiding the cutting tool along a patient-specific tool path using the numerically-controlled instrument while the housing is mounted to the reference guide, the patient-specific tool path determined preoperatively and stored in the numerically-controlled instrument; and

preparing a portion of the bone using the cutting tool.

17. The method of claim 16, wherein the reference guide is an annular ring and wherein mounting the patient specific reference guide on a bone of a joint of a patient further includes mating the annular ring to an annular area around a rim of the acetabulum of the patient.

18. The method of claim 17, wherein preparing the portion of the bone includes preparing the acetabulum of the patient for receiving an implant.

19. The method of claim 17, wherein coupling the housing of a numerically-controlled instrument to a connecting portion coupled to an outer surface of the reference guide includes coupling the housing with a plurality of connecting adaptors coupled to the reference guide.