System for manufacturing and pre-operative inspecting of patient-specific implants

Patent metadata

Field	Value
Publication number	US-12533238-B2
Application number	US-202318376411-A
Country	US
Kind code	B2
Filing date	Oct 3, 2023
Priority date	Sep 22, 2022
Publication date	Jan 27, 2026
Grant date	Jan 27, 2026

Abstract

Systems and methods for verifying the quality of patient specific implants are disclosed. A system can generate implant data, such as design files or fabrication instructions, for manufacturing the implant. The system can manage access to the implant data based on authentication levels. Based on the determined authentication level of the user requesting access to the implant data, the system can permit the user to access some or all of the implant data. The system can perform a quality check on a manufactured implant by scanning the manufactured implant to identify any errors in the manufactured implant.

First claim

What is claimed is:

1 . A system comprising:
one or more processors; and one or more memories storing instructions that, when executed by the one or more processors, cause the system to perform a process comprising:
fabricating, using a manufacturing machine, a patient-specific orthopedic implant based on a virtual three-dimensional model of a patient-specific orthopedic implant;
scanning, via one or more scanners, the patient-specific orthopedic implant to obtain scan data associated with fabricating of the patient-specific orthopedic implant;
obtaining a manufacturing quality threshold for the patient-specific orthopedic implant based on one or more manufacturing characteristics and a surgical plan for implantation of the patient-specific orthopedic implant in a patient;
determining automatically whether the patient-specific orthopedic implant meets the manufacturing quality threshold for the patient-specific orthopedic implant based on the scan data;
in response to the patient-specific orthopedic implant not meeting the manufacturing quality threshold,
identifying at least one manufacturing adjustment for manufacturing another patient-specific orthopedic implant that meets the manufacturing quality threshold; and

in response to the patient-specific orthopedic implant meeting the manufacturing quality threshold,
approving the patient-specific orthopedic implant.

2 . The system of claim 1 , wherein the process further comprises:
manufacturing the patient-specific orthopedic implant according to an implant-manufacturing subscription.

3 . The system of claim 1 , wherein the process further comprises:
receiving a patient data set of the patient; generating, based on the patient data set, a design of the patient-specific orthopedic implant for the patient; and generating fabrication instructions for the manufacturing machine to manufacture the patient-specific orthopedic implant according to the design for the patient.

4 . The system of claim 1 , wherein the scan data includes at least one of lattice density, number of struts, or shape of the patient-specific orthopedic implant.

5 . The system of claim 1 , wherein
the manufacturing machine is configured to fabricate the patient-specific orthopedic implant using additive manufacturing, and the one or more scanners are configured to obtain additive manufacturing characteristics of the patient-specific orthopedic implant.

6 . The system of claim 1 , wherein the at least one manufacturing adjustment includes at least one of adjustment of lattice density, adjustment of number of struts, or adjustment of a shape of the patient-specific orthopedic implant.

7 . A computer-implemented method of approving a patient-specific orthopedic implant, the method comprising:
fabricating, using a manufacturing machine, a patient-specific orthopedic implant based on a virtual three-dimensional model of a patient-specific orthopedic implant; scanning, via one or more scanners, the patient-specific orthopedic implant to obtain scan data associated with fabricating of the patient-specific orthopedic implant; obtaining a manufacturing quality threshold for the patient-specific orthopedic implant based on one or more manufacturing characteristics and a surgical plan for implantation of the patient-specific orthopedic implant in a patient; determining automatically whether the patient-specific orthopedic implant meets the manufacturing quality threshold for the patient-specific orthopedic implant based on the scan data; in response to the patient-specific orthopedic implant not meeting the manufacturing quality threshold,
identifying at least one manufacturing adjustment for manufacturing another patient-specific orthopedic implant that meets the manufacturing quality threshold; and
in response to the patient-specific orthopedic implant meeting the manufacturing quality threshold,
approving the patient-specific orthopedic implant.

8 . The method of claim 7 , further comprising:
manufacturing the patient-specific orthopedic implant according to an implant-manufacturing subscription.

9 . The method of claim 7 , further comprising:
receiving a patient data set of the patient; generating, based on the patient data set, a design of the patient-specific orthopedic implant for the patient; and generating fabrication instructions for the manufacturing machine to manufacture the patient-specific orthopedic implant according to the design for the patient.

10 . The method of claim 7 , wherein the scan data includes at least one of lattice density, number of struts, or shape of the patient-specific orthopedic implant.

11 . The method of claim 7 , wherein
the manufacturing machine is configured to fabricate the patient-specific orthopedic implant using additive manufacturing, and the one or more scanners are configured to obtain additive manufacturing characteristics of the patient-specific orthopedic implant.

12 . The method of claim 7 , wherein the at least one manufacturing adjustment includes at least one of adjustment of lattice density, adjustment of number of struts, or adjustment of a shape of the patient-specific orthopedic implant.

13 . A non-transitory computer-readable medium storing instructions that, when executed by a computing system, cause the computing system to perform operations for approving a patient-specific orthopedic implant, the operations comprising:
fabricating, using a manufacturing machine, a patient-specific orthopedic implant based on a virtual three-dimensional model of a patient-specific orthopedic implant; scanning, via one or more scanners, the patient-specific orthopedic implant to obtain scan data associated with fabricating of the patient-specific orthopedic implant; obtaining a manufacturing quality threshold, wherein the manufacturing quality threshold is based on
one or more manufacturing characteristics of the patient-specific orthopedic implant, and
a surgical plan for implantation of the patient-specific orthopedic implant in a patient;
determining automatically whether the patient-specific orthopedic implant meets the manufacturing quality threshold based on the scan data; in response to the patient-specific orthopedic implant not meeting the manufacturing quality threshold,
identifying at least one manufacturing adjustment for manufacturing another patient-specific orthopedic implant that meets the manufacturing quality threshold; and
in response to the patient-specific orthopedic implant meeting the manufacturing quality threshold,
approving the patient-specific orthopedic implant.

14 . The non-transitory computer-readable medium of claim 13 , wherein the operations further comprise:
manufacturing the patient-specific orthopedic implant according to an implant-manufacturing subscription.

15 . The non-transitory computer-readable medium of claim 13 , wherein the operations further comprise:
receiving a patient data set of the patient; generating, based on the patient data set, a design of the patient-specific orthopedic implant for the patient; and generating fabrication instructions for the manufacturing machine to manufacture the patient-specific orthopedic implant according to the design for the patient.

16 . The non-transitory computer-readable medium of claim 13 , wherein the scan data includes at least one of lattice density, number of struts, or shape of the patient-specific orthopedic implant.

17 . The non-transitory computer-readable medium of claim 13 , wherein
the manufacturing machine is configured to

Assignees

• Carlsmed Inc

Inventors

• Hussain Shariq
• Casey Niall Patrick
• Cordonnier Michael J

Classifications

• G05B2219/35012

  Cad cam · CPC title

• A61F2002/30953

  using a remote computer network, e.g. Internet · CPC title

• A61F2002/30952

  using CAD-CAM techniques or NC-techniques · CPC title

• G05B19/4099

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• A61F2/30942 Primary

  for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques · CPC title