Patient-specific implant design and manufacturing system with a surgical implant positioning manager

Patent metadata

Field	Value
Publication number	US-12588951-B2
Application number	US-202519082149-A
Country	US
Kind code	B2
Filing date	Mar 17, 2025
Priority date	Feb 6, 2023
Publication date	Mar 31, 2026
Grant date	Mar 31, 2026

Abstract

Systems and methods for designing and implementing patient-specific surgical procedures and/or medical devices are disclosed. In some embodiments, a method includes receiving intra-operative data during a surgical procedure to install a patient-specific implant in a patient. The system can compare the intra-operative data to a pre-operative plan to determine whether the implant is positioned and located according to the pre-operative plan.

First claim

What is claimed is:

1 . A method comprising:
obtaining at least one image of an implant located in a patient; obtaining a virtual anatomical model of the patient; performing an anatomical alignment routine by
synchronizing virtual anatomical features of the virtual anatomical model with corresponding anatomical features in the at least one image,
comparing a position of the implant in the at least one image to a planned position of a virtual implant of the virtual anatomical model, wherein the comparison is based on the synchronized virtual anatomical features and the corresponding anatomical features, and
causing display, via a user interface, of a first annotation for positioning the implant at the planned position based on the comparison; and
repeating the anatomical alignment routine to determine the implant is positioned at an acceptable location in the patient based on the comparison, wherein the acceptable location is identified by a second annotation within the user interface and is within a maximum acceptable distance from a target location for the implant, wherein the first annotation is different from the second annotation.

2 . The method of claim 1 , wherein
the at least one image includes a fluoroscopic image, the synchronizing includes manipulating the virtual anatomical model and/or the at least one image according to a best fit routine, and the anatomical alignment routine is repeated using images of the patient showing the implant at another location for achieving a planned anatomical alignment.

3 . The method of claim 2 , wherein synchronizing the virtual anatomical features with the corresponding anatomical features includes
manipulating the virtual anatomical model and/or the at least one image by at least one of zooming, stretching, or rotating the virtual anatomical model to align the virtual anatomical features of the virtual anatomical model with the corresponding anatomical features in the at least one image.

4 . The method of claim 1 , wherein the anatomical alignment routine is performed to determine whether a new position of the implant is a new acceptable location.

5 . The method of claim 1 , further comprising using a trained machine learning engine to perform the anatomical alignment routine.

6 . The method of claim 1 , further comprising sequentially receiving additional images of the patient to repeatedly perform the anatomical alignment routine using a respective one of the additional images.

7 . The method of claim 1 , further comprising:
retrieving a patient-specific surgical plan for the patient; generating instructions for moving the implant toward the target location in the patient-specific surgical plan; and causing the instructions to be intra-operatively outputted to assist with repositioning of the implant.

8 . The method of claim 1 , wherein the first annotation includes one or more measurements of the comparison or a distance from a current position of the implant to the planned position.

9 . The method of claim 1 , wherein the second annotation includes a rectangular window that changes color.

10 . 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:
obtaining at least one image of an implant located in a patient;
obtaining a virtual anatomical model of the patient;
performing an anatomical alignment routine by
synchronizing virtual anatomical features of the virtual anatomical model with corresponding anatomical features in the at least one image,
comparing a position of the implant in the at least one image to a planned position of a virtual implant of the virtual anatomical model, wherein the comparison is based on the synchronized virtual anatomical features and the corresponding anatomical features, and
causing display, via a user interface, of a first annotation for positioning the implant at the planned position based on the comparison; and

repeating the anatomical alignment routine to determine the implant is positioned at an acceptable location in the patient based on the comparison, wherein the acceptable location is identified by a second annotation within the user interface and is within a maximum acceptable distance from a target location for the implant, wherein the first annotation is different from the second annotation.

11 . The system of claim 10 , wherein
the at least one image includes a fluoroscopic image, the synchronizing includes manipulating the virtual anatomical model and/or the at least one image according to a best fit routine, and the anatomical alignment routine is repeated using images of the patient showing the implant at another location for achieving a planned anatomical alignment.

12 . The system of claim 11 , wherein synchronizing the virtual anatomical features with the corresponding anatomical features includes
manipulating the virtual anatomical model and/or the at least one image by at least one of zooming, stretching, or rotating the virtual anatomical model to align the virtual anatomical features of the virtual anatomical model with the corresponding anatomical features in the at least one image.

13 . The system of claim 10 , wherein the anatomical alignment routine is performed to determine whether a new position of the implant is a new acceptable location.

14 . The system of claim 10 , further comprising using a trained machine learning engine to perform the anatomical alignment routine.

15 . The system of claim 10 , wherein the process further comprises sequentially receiving additional images of the patient to repeatedly perform the anatomical alignment routine using a respective one of the additional images.

16 . The system of claim 10 , wherein the process further comprises:
retrieving a patient-specific surgical plan for the patient; generating instructions for moving the implant toward the target location in the patient-specific surgical plan; and causing the instructions to be intra-operatively outputted to assist with repositioning of the implant.

17 . A non-transitory computer-readable medium storing instructions that, when executed by a computing system, cause the computing system to perform operations comprising:
obtaining at least one image of an implant located in a patient; obtaining a virtual anatomical model of the patient; performing an anatomical alignment routine by
synchronizing virtual anatomical features of the virtual anatomical model with corresponding anatomical features in the at least one image,
comparing a position of the implant in the at least one image to a planned position of a virtual implant of the virtual anatomical model, wherein the comparison is based on the synchronized virtual anatomical features and the corresponding anatomical features, and
causing display, via a user interface, of a first annotation for positioning the implant at the planned position based on the comparison; and
repeating the anatomical alignment routine to determine the implant is positioned at an acceptable location in the patient based on the comparison, wherein the acceptable location is identified by a second annotation within the user interface and is within a maximum acceptable distance from a target location for the implant, wherein the first annotation is different from the second annotation.

18 . The non-transitory computer-readable medium of claim 17 , wherein
the at least one image includes a fluoroscopic

Assignees

• Carlsmed Inc

Inventors

• Casey Niall Patrick
• Nicolau Rodrigo Junqueira
• Hussain Syed Shariq
• Pennal Jeffery
• Chen Matthew

Classifications

• G06T19/20

  Editing of three-dimensional [3D] images, e.g. changing shapes or colours, aligning objects or positioning parts · CPC title

• G06T2219/2004

  Aligning objects, relative positioning of parts · CPC title

• A61B2034/104

  Modelling the effect of the tool, e.g. the effect of an implanted prosthesis or for predicting the effect of ablation or burring · CPC title

• A61B2034/256

  having a database of accessory information, e.g. including context sensitive help or scientific articles · CPC title

• A61B2034/252

  indicating steps of a surgical procedure · CPC title