A method of constructing a patient-specific orthopedic implant comprising: (a) comparing a patient-specific abnormal bone model, derived from an actual anatomy of a patient's abnormal bone, with a reconstructed patient-specific bone model, also derived from the anatomy of the patient's bone, where the reconstructed patient-specific bone model reflects a normalized anatomy of the patient's bone, and where the patient-specific abnormal bone model reflects an actual anatomy of the patient's bone including at least one of a partial bone, a deformed bone, and a shattered bone, wherein the patient-specific abnormal bone model comprises at least one of a patient-specific abnormal point cloud and a patient-specific abnormal bone surface model, and wherein the reconstructed patient-specific bone model comprises at least one of a reconstructed patient-specific point cloud and a reconstructed patient-specific bone surface model; (b) optimizing one or more parameters for a patient-specific orthopedic implant to be mounted to the patient's abnormal bone using data output from comparing the patient-specific abnormal bone model to the reconstructed patient-specific bone model; and, (c) generating an electronic design file for the patient-specific orthopedic implant taking into account the one or more parameters.

Methods and systems for providing feedback to guide selection of an artificial bone flap. A user interface for planning a neurosurgical procedure is provided, the neurosurgical procedure including closing of an opening in a portion of a patient's skull using an artificial bone flap. 3D dimensions of the opening are determined using at least pre-operative three-dimensional (3D) imaging data. One or more parameters for selecting an artificial bone flap are determined, where the one or more parameters are based on at least the 3D dimensions of the opening. Output indicating one or more recommended available artificial bone flaps suitable for closing the opening is provided, the recommendation being based on the determined one or more parameters.

A method of forming a patient-specific-bone-graft cage based on a patient-specific bone graft cage computer model that is based on a contour of a surface of the bone defining a void, and/or a patient-specific-bone-graft cage that includes a plurality of apertures, that terminate at a location between a front surface and a back surface of the patient-specific-bone-graft cage, for receipt of bone graft material. The patient-specific-bone-graft cage can construct an essential portion (including complex thin anatomical structures) of or substantially the entirety of the mid-face region (e.g., to fill a void in a damaged orbital region), which enables an improved structure reproduction and simplification for the surgeon. For example, the patient-specific-bone-graft cage may be formed based on the contour of the periphery defining the void in the damaged region, and require less modification by a surgeon compared to graft cages formed only by mirroring techniques or normalized models.

Embodiments of the invention described herein thus provide systems and methods for providing improved surgical implants. Embodiments of the implants may include a thin porous sheet formed on a mandrel. The porous sheet that is formed has an interconnected pore structure that may be compressed by a heat compression mold without losing porosity. Additional membrane materials or other layer materials may be applied to one of the face surfaces of the porous sheet or to one of the edges of the porous sheet. For example, a solid membrane surface may be compressed, bonded, welded, or secured a surface face or an edge of the porous sheet. The solid membrane may be compressed or laminated to the upper surface, lower surface, or both. The solid membrane may be welded to at least one edge of the porous sheet (by, for example, being butt welded, thermally bonded, or heat compressed to the at least one edge).

An anatomy-specific implant for neuroplastic surgery. The implant includes a soft tissue implant component designed within and adapted to replace or restore missing soft tissue in a skull, joint or spine of the patient, wherein the soft tissue implant component is adapted to be coupled by an interdigitated connection to a rigid component. The rigid component can be a skull implant adapted to replace missing cranial or vertebral bone, or healthy cranial or vertebral bone, either of which can have downward extending catheters for medicinal brain or spinal cord infusion to help bypass the blood-brain barrier via multiphase flow. The soft tissue implant may include a functional component having neurotechnologies such as MRI-lucent pumps, Bluetooth connection systems, refillable diaphragms, remote imaging devices, wireless charging capabilities, and/or informative biosensors. The soft tissue implant component may be interchangeable with another soft tissue implant component in plug-and-play fashion.

A surrogate multilayered material and manufacturing method thereof includes a first fiber reinforced layer, the first reinforced layer including a crosslinked polymer and fibers, and a second fiber reinforced layer, the second reinforced layer including the crosslinked polymer and the fibers. A foam layer is disposed between the first and second fiber reinforced layers. Opposite faces of the foam layer are in direct contact with the first fiber reinforced layer and the second fiber reinforced layer. The foam layer has a compressive strength of about 3.5 to about 4.5 MPa, when measured as per ASTM-D-1621-73, and a shear strength of 1.50 to about 2.15 MPa, when measured as per ASTM-C-273.

Methods and apparatus are provided for forming a patient-specific surgical implant based on mold system. The apparatus comprises a forming tool and a mold that may be generated using imaging and processing techniques and rapid prototyping methods. The mold apparatus includes at least two non-adjacent surface features for securing an implant forming material (such as a titanium mesh) during the forming process, enabling the implant forming material to be stretched beyond its elastic and thus permanently deformed with the correct patient-specific curvature. The implant may include one or more anatomic surface features for guidance and registration when transferring the implant to a patient.

Provided is a method for forming an implant with an autonomous manufacturing device. The method includes accessing a first computer-readable reconstruction of a being's anatomy; accessing a second computer-readable reconstruction of an implant; accessing a third computer-readable reconstruction comprising the first computer-readable reconstruction superimposed with the second computer readable reconstruction; generating at least one computer-readable trace from a point cloud; and forming an implant with an autonomous manufacturing device, wherein the autonomous manufacturing device forms the implant into a shape defined by at least one dimension of the computer-readable trace.

The present disclosure is directed to an expandable medical implant for the repair of cranium defects in adolescent patients. The implants of the present disclosure can include a plurality of interconnected links that are movable with respect to each other as the underlying cranium grows and expands.

Embodiments of the present disclosure relate generally to an orbital floor implant (10). One embodiment provides an implant with a first surface that is a fully porous, bone-side layer (16) and a second surface that is a non-porous, orbital content-side layer (18). The implant material itself may be polymeric material throughout, without the need for an embedded mesh or other support matrix. The implant is provided in a pre-shaped configuration and is of a material that allows it to be bent for shaping purposes. An extending tab (12) with eyelet portion/opening (14) can enhance securement options to a patient's bone.