Systems and methods for monitoring an operative site during a surgical procedure using a computer controlled surgical device. In general, the methods include the steps of processing one or more defined cutting paths having one or more cut regions; determining a correlation between the cut region and one or more critical regions to generate an alert, wherein the alert indicates a movable end-effector is within a defined proximity of the critical region; and requiring a user acknowledgment of the alert to allow processing of the cutting path to continue. Also described herein are systems and methods for minimizing user fatigue during a semi-computer controlled surgical procedure. In general, the methods includes the step of requiring a user generated acknowledgment in response to a computer generated alert, wherein the user acknowledgment is generated using a user controller, the user controller being minimally intrusive to the user experience.

A surgical robotic system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. Controller(s) generate a first tool path to remove a first portion of material from the bone and control the manipulator to position the tool for movement along the first tool path to remove the first portion. The controller(s) sense interaction between the tool and the bone during movement of the tool along the first tool path and generate a second tool path to remove a second portion of material from the bone. Generation of the second tool path is based, at least in part, on the sensed interaction between the tool and the bone during movement along the first tool path. The controller(s) control the manipulator to position the tool for movement along the second tool path to remove the second portion.

A method for producing bone grafts using 3-D printing is employed using a 3-D image of a graft location to produce a 3-D model of the graft. This is printed using a 3-D printer and a printing medium that produces a porous, biocompatible, biodegradable material that is conducive to osteoinduction. For example, the printing medium may be PCL, PLLA, PGLA, or another approved biocompatible polymer. In addition such a method may be useful for cosmetic surgeries, reconstructive surgeries, and various techniques required by such procedures. Once the graft is placed, natural bone gradually replaces the graft.

A method for producing bone grafts using 3-D printing is employed using a 3-D image of a graft location to produce a 3-D model of the graft. This is printed using a 3-D printer and a printing medium that produces a porous, biocompatible, biodegradable material that is conducive to osteoinduction. For example, the printing medium may be PCL, PLLA, PGLA, or another approved biocompatible polymer. In addition such a method may be useful for cosmetic surgeries, reconstructive surgeries, and various techniques required by such procedures. Once the graft is placed, natural bone gradually replaces the graft.

A surgical system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. A navigation system includes a localizer, a first tracker coupled to the robotic manipulator or the tool, and a second tracker coupled to a workpiece. Controller(s) determine, from the navigation system, a pose of the tool relative to the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a first portion from the workpiece with the tool and sense interaction between the tool and the workpiece during removal of the first portion to detect a density of the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a second portion from the workpiece with the tool, wherein a cutting depth for the second portion is based, at least in part, on the detected density.

A method for producing bone grafts using 3-D printing is employed using a 3-D image of a graft location to produce a 3-D model of the graft. This is printed using a 3-D printer and a printing medium that produces a porous, biocompatible, biodegradable material that is conducive to osteoinduction. For example, the printing medium may be PCL, PLLA, PGLA, or another approved biocompatible polymer. In addition such a method may be useful for cosmetic surgeries, reconstructive surgeries, and various techniques required by such procedures. Once the graft is placed, natural bone gradually replaces the graft.

Robotic system and methods for robotic arthroplasty. The robotic system includes a machining station and a guidance station. The guidance station tracks movement of various objects in the operating room, such as a surgical tool, a humerus of a patient, and a scapula of the patient. The guidance station tracks these objects for purposes of displaying their relative positions and orientations to the surgeon and, in some cases, for purposes of controlling movement of the surgical tool relative to virtual cutting boundaries or other virtual objects associated with the humerus and scapula to facilitate preparation of bone to receive a shoulder implant system.

Robotic systems and methods for robotic arthroplasty. The robotic system includes a machining station and a guidance station. The guidance station tracks movement of various objects in the operating room, such as a surgical tool, a humerus of a patient, and a scapula of the patient. The guidance station tracks these objects for purposes of controlling movement of the surgical tool relative to virtual cutting boundaries or other virtual objects associated with the humerus and scapula to facilitate preparation of bone to receive a shoulder implant system. The virtual objects are located based on density data of the bone such that, when one or more shoulder implants are fully seated in the bone, distal portions of the implants are located in a first region of the bone having a density characteristic greater than an adjacent second region of the bone.

A method of operating a robotic system to efficiently remove material from a workpiece based on a density distribution of the material of the workpiece. The density distribution of the material of the workpiece is determined from a three-dimensional representation and evaluated by classifying the plurality of points or voxels into a first density classification and a second density classification. A navigation computer generates a first tool path and a second tool path for the tool based on the evaluated density distribution. The first tool path is associated with the first density classification, and the second tool path is associated with the second density classification. The position of the tool relative to the workpiece is tracked with a navigation computer and controlled with a manipulator controller based on the generated tool path to remove material along the first tool path, and remove material along the second tool path.

A method, computer program product and computer system for mode selection of a prosthesis is provided. A processor of a wearable device receives a first input from a user. A processor of a wearable device determines the first input indicates a change to a mode of operation of the prosthesis. A processor of a wearable device sends a first command to the prosthesis to change the mode of operation of the prosthesis.