Implant with patient-specific porous structure

• US 9,827,106 B2
• Filed: 11/18/2015
• Issued: 11/28/2017
• Est. Priority Date: 02/02/2012
• Status: Active Grant

• Current Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Biomet Manufacturing, LLC (Zimmer Biomet Holdings, Inc.)
• Inventors: Hensley, Erin L., Fox, Duke A., Gupta, Gautam
• Primary Examiner(s): Dukert, Brian
• Application Number:
  US14/944,742
• Publication Number:
  US 20160067048A1
• Time in Patent Office: 741 Days
• 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 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30769 madreporic
• CPC Class Codes: A61F 2002/30841 Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/30878 with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30948 using computerized tomography, i.e. CT scans
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture

Abstract

A method of manufacturing a joint implant for a joint of a specific patient includes obtaining a three-dimensional image of a bone of the joint of the specific patient from medical imaging scans of the bone of the patient and determining on the three-dimensional image a resection plane for contacting a corresponding planar surface of the joint implant for the specific patient. The method includes determining a three-dimensional image of a porous structure of a bone layer along the resection plane from the medical imaging scans of the patient. The joint implant is manufactured with a layer of a patient-specific porous construct attached to the planar surface of the joint implant. The layer of the patient-specific porous construct substantially replicates the porous structure of the bone layer of the specific patient.

Claims

1. An orthopedic implant manufactured for a specific patient comprising:

a femoral knee implant core having an interior multiplanar surface including a plurality of planar surfaces configured to correspond to a plurality of corresponding resection planes of a distal femoral bone of the specific patient; and

a patient-specific porous construct including a plurality of layers attached to corresponding planar surfaces of the femoral knee implant, each layer constructed to replicate a three-dimensional porous structure of a bone layer along a corresponding resection plane of femoral bone, the porous structure determined from medical imaging scans of the un-resected femoral bone;

wherein the patient-specific porous construct three-dimensionally varies throughout each layer in a patient-specific manner according to the three-dimensional porous structure of the bone layer.

2. The orthopedic implant of claim 1, wherein the plurality of planar surfaces includes five surfaces.

3. The orthopedic implant of claim 1, wherein the plurality of planar surfaces includes posterior, anterior and distal surfaces.

4. The orthopedic implant of claim 3, wherein the plurality of planar surfaces includes posterior chamfer and anterior chamfer surfaces.

5. The orthopedic implant of claim 1, wherein the implant core includes non-porous material.

6. The orthopedic implant of claim 1, wherein the implant core includes an exterior articulating surface.

7. The orthopedic implant of claim 1, wherein the porous structure is determined from medical imaging scans with a resolution of a few microns for voxel size.

8. The orthopedic implant of claim 1, wherein each layer is constructed to replicate a three-dimensional porous structure of a bone layer along a corresponding resection plane of femoral bone such that the patient-specific construct mirrors the porous structure of the bone layer along the resection planes.

9. The orthopedic implant of claim 1, wherein the patient-specific porous construct three-dimensionally varies throughout a thickness of each layer to correspond to three-dimensional variability of the porous structure.

10. The orthopedic implant of claim 9, wherein the patient-specific porous construct three-dimensionally varies throughout a planar section of each layer to correspond to three-dimensional variability of the porous structure.

11. An orthopedic implant manufactured for a specific patient comprising:

an implant core comprising;

an outer joint-facing surface; and

an inner bone engagement surface having at least one planar surface constructed to correspond to a corresponding resection plane of a bone of the specific patient; and

a patient-specific porous construct including a layer attached to the planar surface of the orthopedic implant, the patient-specific porous construct mirroring a porous structure of a bone layer at the resection plane such that the layer of the patient-specific porous construct is an inverse of the porous structure of the bone layer of the bone at the resection plane.

12. The orthopedic implant of claim 11, wherein the porous structure is determined from medical imaging scans with a resolution of a few microns for voxel size.

13. The orthopedic implant of claim 11, wherein the patient-specific porous construct has a thickness and the patient-specific porous construct varies within the thickness.

14. The orthopedic implant of claim 11, wherein the patient-specific porous construct comprises porous metal.

15. The orthopedic implant of claim 11, wherein the implant core comprises:

a tibial tray comprising;

anchoring members extending from the inner bone engagement surface; and

locking tabs disposed in the outer joint-facing surface.

16. The orthopedic implant of claim 11, wherein the implant core comprises:

a femoral knee implant comprising;

an inner bone engagement surface comprising a plurality of planar surfaces constructed to correspond to corresponding resection planes of the bone of the specific patient; and

an articulating surface defining the outer joint-facing surface.

17. The orthopedic implant of claim 16, wherein each of the plurality of planar surfaces has a different patient-specific porous construct.

18. The orthopedic implant of claim 11, wherein the patient-specific porous construct three-dimensionally varies throughout the layer in a patient-specific manner according to a three-dimensional variability of the porous structure.

19. The orthopedic implant of claim 18, wherein the layer is constructed to replicate point-by-point a three-dimensional porous structure of a bone layer along the resection plane of bone such that the patient-specific porous construct congruently continues the variability of the porous structure of the bone layer.

20. The orthopedic implant of claim 19, wherein the porous structure is determined from medical imaging scans of the un-resected bone.