Backup surgical instrument system and method

  • US 9,918,740 B2
  • Filed: 06/20/2012
  • Issued: 03/20/2018
  • Est. Priority Date: 02/27/2006
  • Status: Active Grant
First Claim
Patent Images

1. A method for assembling surgical kits for use during a surgery, comprising:

  • obtaining image information for anatomy of a patient;

    generating a pre-operative surgical plan for performing a procedure on the patient using the image information;

    creating a three-dimensional model of a bone from the patient using the image information;

    manufacturing a patient-specific instrument including a three-dimensional contoured engagement surface configured to nest into a portion of a native anatomy in a single location, the three-dimensional contoured engagement surface generated using the image information;

    obtaining a set of surgical instruments based on the pre-operative surgical plan, the set of surgical instruments including at least;

    a general instrument selected from a predetermined group of off-the-shelf instruments, the general instrument being a non-disposable type;

    a first size-specific instrument having a first size selected from predetermined sizes;

    the patient-specific instrument; and

    a surgeon-specific instrument selected based on a surgeon preference for performing the procedure, the surgeon-specific instrument being different than the selected general instrument, first size-specific instrument, and patient-specific instrument, the surgeon-specific instrument comprising one of a plurality of accepted instruments for performing a surgical task, the plurality of accepted instruments being alternatives to each other for achieving the same result;

    packaging a surgeon instrument kit containing the set of surgical instruments in sterilized form in a container;

    delivering the surgeon instrument kit to a surgeon for use during the surgery;

    staging the surgeon instrument kit relative to an operating room used for the surgery; and

    individually packaging a backup instrument into a backup instrument package based on and separate from the surgeon instrument kit, the backup instrument package containing only one sterilized replacement instrument for one of the surgical instruments, the sterilized replacement instrument being a duplicate of the one of the surgical instruments.

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