Method for producing patient-specific plate

Patent metadata

Field	Value
Publication number	US-10548668-B2
Application number	US-201615188058-A
Country	US
Kind code	B2
Filing date	Jun 21, 2016
Priority date	Sep 12, 2012
Publication date	Feb 4, 2020
Grant date	Feb 4, 2020

Abstract

A method of making a patient specific surgical orthopedic implant includes obtaining a virtual model of the orthopedic implant that is configured to fit over a particular tissue body, and virtually designing holes of the orthopedic implant.

First claim

What is claimed is:

1. A method of preparing an orthopedic implant, the method comprising:
identifying a predetermined section of a virtual three-dimensional model of a tissue body, the predetermined section indicating a location, within the tissue body, of nerves, teeth, other specific tissue portions, or hardware;
overlaying, via a software program executed by a computing device, a virtual three-dimensional model of an implant body over the virtual three-dimensional model of the tissue body so as to define a manipulated virtual three-dimensional model of the implant body;
designing, via the software program, a virtual three-dimensional hole within the virtual three-dimension model of the implant body such that a virtual three-dimensional model of a fastener that is fully seated within the virtual three-dimensional hole does not extend into the predetermined section;
generating manufacturing instructions for transmission to a manufacturing machine that is configured to construct a patient specific orthopedic implant that corresponds to the manipulated virtual three-dimensional model of the implant body; and
transmitting the manufacturing instructions to the manufacturing machine.

2. The method of claim 1 , wherein designing the virtual three-dimensional hole further comprises orienting an axis of the virtual three-dimensional hole at an acute angle relative to an axis that is orthogonal to at least one of an inner surface and an outer surface of the virtual three-dimensional model of the implant body.

3. The method of claim 2 , wherein the acute angle is between about zero degrees and about 15 degrees.

4. The method of claim 2 , wherein the acute angle is greater than 15 degrees.

5. The method of claim 1 , further comprising:
designing a second virtual three-dimensional hole within the virtual three-dimensional model of the implant body; and
orienting the second virtual three-dimensional hole such that a second virtual three-dimensional model of a fastener that is fully seated within the second virtual three-dimensional hole does not extend into the predetermined section.

6. The method of claim 5 , wherein an axis of the virtual three-dimensional hole is angularly offset relative to an axis of the second virtual three-dimensional hole.

7. The method of claim 5 , wherein the virtual three-dimensional model of the tissue body defines a first segment and a second segment separated from the first segment, the virtual three-dimensional hole overlies one of the first and second segments, and the second virtual three-dimensional hole overlies the other of the first and second segments.

8. The method of claim 6 , wherein the virtual three-dimensional model of the implant body includes a first body portion and a second body portion angularly offset relative to the first body portion, the virtual three-dimensional hole is located in the first body portion, and the second virtual three-dimensional hole is located in the second body portion.

9. The method of claim 1 , wherein the virtual three-dimensional model of the implant body includes:
a first body portion;
a second body portion angularly offset relative to the first body portion; and
a third body portion angularly offset relative to each of the first and second body portions.

10. The method of claim 9 , wherein:
the virtual three-dimensional model of the tissue body includes 1) an anterior surface of a mandible, 2) a lateral surface of the mandible, and 3) at least a portion of a ramus of the mandible; and
the overlaying step further comprises 1) overlaying the first body portion over the anterior surface of the mandible, 2) overlaying the second body portion over the lateral surface of the mandible, and 3) overlaying the third body portion over the at least a portion of the ramus of the mandible.

11. The method of claim 10 , wherein the virtual three-dimensional hole is a first hole located within the first body portion, and the method further comprises:
designing and orienting a second virtual three-dimension hole within the second body portion such that a second virtual three-dimensional model of a fastener that is fully seated within the second virtual three-dimensional hole does not occupy the same virtual three-dimensional space as the predetermined section or the virtual three-dimensional model of the fastener fully seated within the first hole.

12. The method of claim 11 , further comprising designing and orienting a third virtual three-dimension hole within the third body portion such that a third virtual three-dimensional model of a fastener that is fully seated within the third virtual three-dimensional hole does not occupy the same virtual three-dimensional space as any of the predetermined section, the virtual three-dimensional model of the fastener fully seated within the first hole, and the second virtual three-dimensional model of the fastener fully seated within the second hole.

13. The method of claim 9 , wherein the virtual three-dimensional model of the implant body includes:
a fourth body portion angularly offset relative to each of the first, second and third body portions; and
a fifth body portion angularly offset relative to each of the first, second, third, and fourth body portions.

14. The method of claim 13 , wherein the fourth body portion opposes the second body portion and the fifth body portion opposes the third body portion.

15. The method of claim 1 , wherein:
the virtual three-dimensional model of the tissue body defines a first segment and a second segment separated from the first segment; and
the overlaying step further comprises overlaying the virtual three-dimensional model of the implant body over the first and second segments.

16. The method of claim 15 , further comprising identifying an indication of a tissue defect within a third segment of the virtual three-dimensional model of the tissue body located between the first and second segments.

17. The method of claim 16 , further comprising:
designing, via the software program, a second virtual three-dimensional hole within the virtual three-dimension model of the implant body; and
orienting an axis of the second virtual three-dimensional hole such that a second virtual three-dimensional model of a fastener that is fully seated within the second virtual three-dimensional hole 1) extends within the third segment, and 2) does not occupy the same virtual three-dimensional space as the predetermined section or the virtual three-dimensional model of the fastener fully seated within the virtual three-dimensional hole.

18. A method of preparing an orthopedic implant, the method comprising:
identifying, in a virtual three-dimensional model of a tissue body, a predetermined section that indicates a location within the tissue body of nerves, teeth, other specific tissue portions, or hardware;
designing, via a software program executed by a computing device, a virtual three-dimensional model of an implant body that is contoured to fit over the virtual three-dimensional model of the tissue body;
overlaying, via the software program, the virtual three-dimensional model of the implant body over the virtual three-dimensional model of the tissue body so as to define a manipulated virtual three-dimensional model of the implant body;
designing, via the software program, a virtual three-dimensional hole within the virtual three-dimension model of the implant body such that a virtual three-dimensional model of a fastener fully seated within the virtual three-dimensional hole does not extend into the predetermined secti

Assignees

• Depuy Synthes Products Inc

Inventors

• Furrer André
• Zillig Timo
• Davison Andrew Charles
• Gheorghe Razvan A

Classifications

• G16H50/50

  for simulation or modelling of medical disorders · CPC title

• A61B2017/00526

  Methods of manufacturing · CPC title

• A61B2017/568

  produced with shape and dimensions specific for an individual patient · CPC title

• A61B2034/102

  Modelling of surgical devices, implants or prosthesis · CPC title

• A61B34/10 Primary

  Computer-aided planning, simulation or modelling of surgical operations · CPC title