Systems and methods for manufacturing, preparation and use of blanks in orthopedic implants
Inventors
Miller, Bob • Dion, Ernest A. • Hesketh, David P. • Salinas, Manuel J. • Lang, Philipp
Assignees
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Publication Number
US-11419726-B2
Publication Date
2022-08-23
Expiration Date
Abstract
A blank for use in manufacturing a surgical implant is provided. The blank includes a shape based, at least in part, on one or more features common to a specific type of patient-adapted implants. The blank has dimensions that are equal to or larger than corresponding dimensions of each patient-adapted implant included in the specific type of patient-adapted implants.
Core Innovation
The disclosure describes orthopedic manufacturing using patient-appropriate blanks/templates and fixtures for manufacturing surgical implants. A blank is formed with a shape based, at least in part, on one or more features common to a specific type of patient-adapted implant, and the blank dimensions are equal to or larger than corresponding dimensions of each patient-adapted implant included in the specific type of patient-adapted implant.
The blank accommodates manufacturing in multiple orientations. In one embodiment, the blank is symmetrical about a first axis and is able to accommodate manufacturing the surgical implant in a first orientation or a second orientation, where the second orientation is rotated 180 degrees from the first orientation with respect to the first axis.
The disclosure additionally describes manufacturing flow concepts that compare data for a patient-adapted implant with a CAD model and use machining approaches, including 4D/5D machining, together with patient-adapted fixtures. Fixture concepts include macro chucks and collets that fix implant orientation, peg/peg-location accommodation, and verification/inspection before detaching and further processing such as drag finishing.
Claims Coverage
Two independent claims are directed to a manufacturing blank for a surgical implant based on features common to a specific type of patient-adapted implants, with blank dimensions equal to or larger than corresponding dimensions. Overall, the inventive structure is defined by patient-type-based shape and at-least-as-large dimensions, with additional symmetry/orientation in one claim and integrally formed pegs in the other.
Symmetrical blank with two orientations rotated 180 degrees
A blank for use in manufacturing a surgical implant comprising a shape based, at least in part, on one or more features common to a specific type of patient-adapted implant; dimensions that are equal to or larger than corresponding dimensions of each patient-adapted implant included in the specific type of patient-adapted implant; wherein the blank is symmetrical about a first axis and is able to accommodate manufacturing the surgical implant in a first orientation or a second orientation, wherein the second orientation is rotated 180 degrees from the first orientation with respect to the first axis.
Blank with integrally formed pegs as common features
A blank for use in manufacturing a surgical implant comprising a shape based, at least in part, on one or more features common to a specific type of patient-adapted implant; dimensions that are equal to or larger than corresponding dimensions of each patient-adapted implant included in the specific type of patient-adapted implant; wherein the one or more features common to the specific type of patient-adapted implant comprise integrally formed pegs.
The claim set focuses on a patient-adapted implant type-based blank with at-least-as-large dimensions, where one independent claim adds symmetry to enable a 180-degree rotated second manufacturing orientation, and the other independent claim requires that the shared features include integrally formed pegs.
Stated Advantages
Reduces manufacturing delay versus producing only primary and backup implants.
Reduces manufacturing cost and wastage versus producing only primary and backup implants.
Supports just-in-time replacement from inventory blanks.
Documented Applications
Orthopedic manufacturing of surgical implants using patient-appropriate blanks/templates and patient-adapted fixtures, including femoral implant component and implant types including knee/hip/elbow/shoulder/ankle/wrist/spinal.
Backup creation using inventory blanks to enable just-in-time replacement.
Use of CAD comparisons and machining concepts, including 4D/5D machining, together with patient-adapted fixtures to support orientation fixing and inspection/verification before further processing.
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