Robot specific implant designs with contingent manual instrumentation

Patent metadata

Field	Value
Publication number	US-11291512-B2
Application number	US-202016875173-A
Country	US
Kind code	B2
Filing date	May 15, 2020
Priority date	May 20, 2019
Publication date	Apr 5, 2022
Grant date	Apr 5, 2022

Abstract

A system and method are described herein for creating planar bone cuts on a bone to receive a total knee arthroplasty (TKA) femoral implant. The system includes a robotic surgical device, a computing system, and one or more contingent manual instruments. A surgical plan is generated having instructions for the robotic surgical device to create six or more planar bone cuts on the bone. The robotic surgical device executes the instructions, and in the event the robotic procedure is aborted before completing the six or more planar cuts, the one or more contingent manual instruments are used to create any remaining planar bone cuts. The one or more contingent manual instruments may include a plurality of uniquely arranged guide slots to assist a user in creating one or more remaining planar bone cuts.

First claim

The invention claimed is:

1. A method to prepare a bone to receive an implant having six or more planar surfaces, comprising:
planning a position for an implant having six or more planar surfaces relative to pre-operative bone data; and
preparing the bone with a robotic surgical device to create six or more planar bone cuts complementary to the-six or more planar surfaces; and
creating any remaining planar bone cuts with a manual instrument when the robotic preparation is aborted before the completion of the six or more planar bone cuts.

2. The method of claim 1 wherein the implant is a custom design with a planning software program.

3. The method of claim 2 further comprising manufacturing the implant according to the custom design.

4. The method of claim 1 where the implant is a femoral total knee arthroplasty (TKA) implant.

5. The method of claim 1 wherein the bone is a femur bone.

6. The method of claim 5 further comprising first removing a distal cut plane and creating a pair of peg holes on the femur bone prior to creating any other planar bone cuts.

7. The method of claim 6 wherein the manual instrument is a cut block having a plurality of guide slots to guide a surgical saw to create the remaining planar bone cuts, and a pair of pegs projecting from a bottom surface of the cut block that are placed in the pair of peg holes.

8. The method of claim 1 wherein the manual instrument is a set of cut blocks, wherein each cut block of the set of cut blocks has one or more guide slots at a unique angle and position compared to the other cut blocks of the set of cut blocks.

9. The method of claim 1 wherein the manual instrument comprises a mating surface that is a negative match of a portion of the bone.

10. The method of claim 9 wherein the manual instrument is a three-dimensional (3-D) printed cut guide.

11. The method of claim 1 wherein the manual instrument is a cut block having six or more guide slots.

Assignees

• Think Surgical Inc

Inventors

• Forstein Micah
• Kuznik Kyle

Classifications

• A61B2034/742

  Joysticks · CPC title

• A61B2034/743

  Keyboards · CPC title

• A61B2034/107

  Visualisation of planned trajectories or target regions · CPC title

• A61F2/3859

  Femoral components · CPC title

• A61B34/20 Primary

  Surgical navigation systems; Devices for tracking or guiding surgical instruments, e.g. for frameless stereotaxis · CPC title