Cutting machine for resizing raw implants during surgery

Patent metadata

Field	Value
Publication number	US-10603175-B2
Application number	US-201515529042-A
Country	US
Kind code	B2
Filing date	Nov 24, 2015
Priority date	Nov 24, 2014
Publication date	Mar 31, 2020
Grant date	Mar 31, 2020

Abstract

Provided is a method for forming an implant with an autonomous manufacturing device. The method includes accessing a first computer-readable reconstruction of a being's anatomy; accessing a second computer-readable reconstruction of an implant; accessing a third computer-readable reconstruction comprising the first computer-readable reconstruction superimposed with the second computer readable reconstruction; generating at least one computer-readable trace from a point cloud; and forming an implant with an autonomous manufacturing device, wherein the autonomous manufacturing device forms the implant into a shape defined by at least one dimension of the computer-readable trace.

First claim

What is claimed is:

1. A method for forming an implant with an autonomous manufacturing device, comprising:
accessing a first computer-readable reconstruction of a being's anatomy;
forming an implant corresponding to a portion of the being's anatomy, the implant comprising a polymer, a metal, a bioengineered material, or a combination thereof;
accessing a second computer-readable reconstruction of the implant;
resecting a portion of the being's anatomy creating a boundary defect defining the resected portion of the being's anatomy;
generating at least one computer-readable trace from a point cloud of the boundary defect of the being's anatomy with an anatomical feature removed; and
removing excess material from a periphery of the implant to form the implant into a shape defined by the computer-readable trace.

2. The method of claim 1 , wherein the step of removing includes causing an implant material-removal tool of an autonomous manufacturing device to remove the excess material from the implant.

3. The method of claim 2 , further comprising generating a projected trace from the computer-readable trace, wherein the projected trace comprises a 2D or 3D projected trace, and projecting the projected trace onto the implant.

4. The method of claim 3 , further including the step of accessing a third computer-readable reconstruction comprising the first computer-readable reconstruction superimposed with the second computer readable reconstruction.

5. The method of claim 1 , wherein the computer-readable trace includes information for generating signals to virtually constrain a human-guided cutting tool using an autonomous manufacturing device.

6. The method of claim 5 , wherein the human-guided cutting tool using the autonomous manufacturing device is configured to provide haptic feedback.

7. The method of claim 1 , wherein the step of removing includes removing portions of the implant that are adjacent to a boundary defined by at least one dimension of the computer-readable trace.

8. The method of claim 1 , further comprising fitting the implant onto the being.

9. The method of claim 1 , wherein the wherein the step of forming is performed by an autonomous manufacturing device.

10. The method of claim 9 , wherein the step of removing is performed by the autonomous manufacturing device.

11. The method of claim 10 , wherein the autonomous manufacturing device comprises an articulating arm and an implant material-removal tool detachably connected to an end of the articulating arm.

12. The method of claim 10 , wherein the autonomous manufacturing device comprises an implant material-removal tool disposed on a nonstationary platform and a holding platform on which implant material is attached, wherein the nonstationary platform is configured to advance or retract the implant material-removal tool toward or away from the holding platform.

13. The method of claim 12 , wherein the implant material-removal tool comprises a cutting surface for cutting the implant material.

14. The method of claim 12 , wherein the implant material-removal tool comprises a laser for ablating the implant material.

15. The method of claim 12 , wherein the holding platform comprises a nonstationary platform.

16. The method of claim 12 , wherein the holding platform comprises a stationary platform.

17. The method of claim 1 , wherein the step of removing is performed by an autonomous manufacturing device comprising an implant material-removal tool.

18. The method of claim 17 , wherein the computer-readable trace includes information for generating signals to virtually constrain a human-guided cutting tool using the autonomous manufacturing device with the use of at least one of motor encoders, a position trackable element and/or an electromagnetic trackable element.

19. The method of claim 18 , wherein the human-guided cutting tool comprises a haptic device, wherein the haptic device receives signals generated in response to the signals generated by the at least one of motor encoders, a position trackable element and/or an electromagnetic trackable element in order to generate a haptic response provided by the human-guided cutting tool.

20. The method of claim 1 , the computer-readable trace comprises a virtual or visual representation of a geometry corresponding to a final shape of a resized implant.

21. The method of claim 1 , wherein the implant is formed with a curvature specific to that of the being's anatomy.

22. The method of claim 1 , wherein the step of removing is performed by an autonomous manufacturing device comprising a multi-axis laser cutter machine.

Assignees

• Univ Johns Hopkins

Inventors

• Alambeigi Farshid
• Sefati Shahriar
• Murphy Ryan
• Armand Mehran
• Gordon Chad R
• Liu Shuya

Classifications

• B23K2103/42

  Plastics other than composite materials · CPC title

• A61B2034/2051

  Electromagnetic tracking systems · CPC title

• A61F2/2875

  Skull or cranium (A61F2/2803 takes precedence; joints for temporo-mandibular [TM] joints [TMJ] A61F2/3099) · CPC title

• A61B2034/2055

  Optical tracking systems · CPC title

• A61B2034/304

  including a freely orientable platform, e.g. so called 'Stewart platforms' · CPC title