Customized patient-specific contact segments for orthopaedic surgical instrument using bone silhouette curves

Patent metadata

Field	Value
Publication number	US-2021196291-A1
Application number	US-201916729351-A
Country	US
Kind code	A1
Filing date	Dec 28, 2019
Priority date	Dec 28, 2019
Publication date	Jul 1, 2021
Grant date	—

Abstract

An orthopaedic surgical instrument includes a customized patient-specific surgical instrument having a body. The body has a bone-facing surface and an outer surface positioned opposite the bone-facing surface. The body includes a number of bone-contacting segments raised relative to the bone-facing surface. The bone-contacting segment include negative contours shaped to match corresponding positive contours of a patient's bone. The positive contours correspond to silhouette curves of a three-dimensional model of the patient's bone that correspond to contours of the patient's bone captured in images used to generate the model. The body further includes a number of surgical guides extending from the outer surface to the bone-contacting surface or the bone-facing surfaces. A method associated with the instrument is also disclosed.

First claim

1 . A customized patient-specific surgical instrument comprising a polymeric body including:
a bone-facing surface and an outer surface positioned opposite the bone-facing surface; a first bone-contacting segment coupled to the bone-facing surface and having a bone-contacting surface that is raised relative to the bone-facing surface, wherein the bone-contacting surface defines a customized patient-specific first negative contour shaped to match and receive a corresponding first positive contour of the patient's bone, wherein the first positive contour corresponds to a silhouette curve of a three-dimensional model of the patient's bone, wherein the silhouette curve corresponds to a contour of the patient's bone visible in a first two-dimensional image of the patient's bone that is related to the three-dimensional model; and a surgical guide defined by inner walls that extend from the outer surface to the bone-facing surface or to the bone-contacting surface of the bone-contacting segment.

2 . The surgical instrument of claim 1 , wherein the bone-facing surface is devoid of any negative contour shaped to match and receive a corresponding positive contour of the patient's bone.

3 . The surgical instrument of claim 1 , further comprising:
a second bone-contacting segment coupled to the bone-facing surface and having a bone-contacting surface that is raised relative to the bone-facing surface, wherein the bone-contacting surface of the second bone-contacting segment defines a customized patient-specific second negative contour shaped to match and receive a corresponding second positive contour of the patient's bone, wherein the second positive contour corresponds to a silhouette curve of the three-dimensional model that corresponds to a contour of the patient's bone captured in a second two-dimensional image that is used to generate the three-dimensional model.

4 . The surgical instrument of claim 3 , wherein the second bone-contacting segment is arranged generally perpendicular to the first bone-contacting segment.

5 . The surgical instrument of claim 3 , wherein the first two-dimensional image and the second two-dimensional image are captured in orthogonal imaging planes.

6 . The surgical instrument of claim 1 , wherein the polymeric body includes a base and an elongated first arm coupled to the base, and the first bone-contacting segment extends from the base to a posterior end of the first arm.

7 . The surgical instrument of claim 6 , further comprising:
a second bone-contacting segment coupled to the bone-facing surface and having a bone-contacting surface that is raised relative to the bone-facing surface, wherein the bone-contacting surface of the second bone-contacting segment defines a customized patient-specific second negative contour shaped to match and receive a corresponding second positive contour of the patient's bone, wherein the second positive contour corresponds to a silhouette curve of the three-dimensional model that corresponds to a contour of the patient's bone captured in a second two-dimensional image that is used to generate the three-dimensional model; wherein the second bone-contacting segment extends generally perpendicular to the first bone-contacting segment from a lateral side of the first arm to a medial side of the first arm.

8 . The surgical instrument of claim 6 , further comprising:
a second bone-contacting segment coupled to the bone-facing surface, spaced apart from the first bone-contacting segment, and having a bone-contacting surface that is raised relative to the bone-facing surface, wherein the bone-contacting surface of the second bone-contacting segment defines a customized patient-specific second negative contour shaped to match and receive a corresponding second positive contour of the patient's bone and wherein the second positive contour corresponds to a silhouette curve of the three-dimensional model that corresponds to a contour of the patient's bone captured in the first two-dimensional image; wherein the polymeric body further includes an elongated second arm coupled to the base, and the second bone-contacting segment extends from the base to a posterior end the second arm; and wherein the first bone-contacting segment is positioned on a medial side of the polymeric body and the second bone-contacting segment is positioned on a lateral side of the polymeric body.

9 . The surgical instrument of claim 8 , wherein the bone-facing surface is positioned between the first bone-contacting segment and the second bone-contacting segment, and wherein the bone-facing surface is devoid of any negative contour shaped to match and receive a corresponding positive contour of the patient's bone.

10 . The surgical instrument of claim 8 , further comprising:
a third bone-contacting segment coupled to the bone-facing surface, spaced apart from the first bone-contacting segment and the second bone-contacting segment, and having a bone-contacting surface that is raised relative to the bone-facing surface, wherein the bone-contacting surface of the third bone-contacting segment defines a customized patient-specific third negative contour shaped to match and receive a corresponding third positive contour of the patient's bone, wherein the third positive contour corresponds to a silhouette curve of the three-dimensional model that corresponds to a contour of the patient's bone captured in the first two-dimensional image; wherein the third bone-contacting segment is positioned between the first bone-contacting segment and the second bone-contacting segment.

11 . The surgical instrument of claim 10 , further comprising:
a fourth bone-contacting segment coupled to the bone-facing surface and having a bone-contacting surface that is raised relative to the bone-facing surface, wherein the bone-contacting surface of the fourth bone-contacting segment defines a customized patient-specific fourth negative contour shaped to match and receive a corresponding fourth positive contour of the patient's bone, wherein the fourth positive contour corresponds to a silhouette curve of the three-dimensional model that corresponds to a contour of the patient's bone captured in a second two-dimensional image; and a fifth bone-contacting segment coupled to the bone-facing surface and having a bone-contacting surface that is raised relative to the bone-facing surface, wherein the bone-contacting surface of the fifth bone-contacting segment defines a customized patient-specific fifth negative contour shaped to match and receive a corresponding fifth positive contour of the patient's bone, wherein the fifth positive contour corresponds to a silhouette curve of the three-dimensional model that corresponds to a contour of the patient's bone captured in the second two-dimensional image; wherein the fourth bone-contacting segment extends generally perpendicular to the first bone-contacting segment from a lateral side of the first arm to a medial side of the first arm; and wherein the fifth bone-contacting segment extends generally perpendicular to the second bone-contacting segment from a lateral side of the second arm to a medial side of the second arm.

12 . The surgical instrument of claim 1 , wherein the surgical guide comprises a cutting slot defined by the inner walls.

13 . The surgical instrument of claim 1 , wherein the surgical guide comprises a cylindrical bone-pin guide slot defined by the inner walls.

14 . A method for creating a patient-specific resection guide, the method comprising:
generating a three-dimensional model of a patient's bone based on a plurality of images, wherein each image views the patient's

Assignees

• Depuy Synthes Products Inc

Inventors

• Rhodes James M
• Courtis R Patrick

Classifications

• A61B34/10 Primary

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

• A61B2017/00526

  Methods of manufacturing · CPC title

• A61B2034/105

  Modelling of the patient, e.g. for ligaments or bones · CPC title

• A61B2017/00792

  Plastic surgery · CPC title

• A61B17/1764 Primary

  for the knee · CPC title