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.

An anatomically fitted talar component for use in an ankle replacement system having a body including a talar surface having a portion contoured to approximately or exactly fit with a surface portion of a three dimensional rendering of bone of a talar dome; and a tibial surface configured for forming a joint with a second component of the ankle replacement system. A method of forming the talar component by: (i) obtaining image data of the talar dome, (ii) using the data to create a three-dimensional model of the talar dome, and (iii) forming a body having a talar surface that approximately or exactly fits with a portion of the surface of the three-dimensional model.

The present invention includes a method for generating a three-dimensional model of a bone and generating a cut plan for excavating a portion of the bone according to the cut plan to allow the insertion of a custom implant. In a particular arrangement, the method also includes excavating the bone with an autonomous extremity excavator utilizing the cut plan generated by a processor. In a further arrangement, the method includes generating a digital model of a custom implant and generating, using the digital model, a physical model sharing the same dimensions as the digital module using manufacturing device.

A surgical implant for a proximal carpal row replacement surgery employs a scanned image of each of the scaphoid, lunate and triquetrum bones for generating a unitary, homogeneous model defining a fused shape for implantation as the proximal carpal row. The implant utilizes a contralateral image of healthy bones of the patient for generating the replacement model, and employs shrink-wrap and smoothing processing to generate the unitary replacement. The resulting implant replaces the intercalary bone structures of the scaphoid, lunate and triquetrum with a single appliance, and is slideably engaged with the distal carpal row via a surgical tunnel and tethered by a resectioned tendon, ligament, or other connective member. The implant facilitates wrist function since the unitary implant replaces skeletal structures that are encapsulated by adjacent bones and frequently move as a unit, while eliminating gaps, voids and ligaments between the intercalary structure.

Disclosed herein are a method and system for producing a digital model of a customised device, comprising the steps of: importing a first digital file of a base part; importing a second digital file of a target shape; determining a warping interpolation function based on source point positions associated with the base part and target point positions associated with the target shape; and applying the warping interpolation function to the points of said base part to generate a model of said customised device.

An implantable composition, method of making and using the implantable composition is provided. The implantable composition comprising a first set of fibers and a second set of fibers, the first set of fibers manufactured to have a first binding surface, the second set of fibers manufactured to have a second binding surface, the first binding surface of the first set of fibers configured to bind at least at or near the second binding surface of the second set of fibers and the second set of fibers configured to bind at least at or near the first binding surface of the first set of fibers.

A method of designing an orthopedic implant comprising: (a) iteratively evaluating possible shapes of a dynamic orthopedic implant using actual anatomical shape considerations and kinematic shape considerations; and, (b) selecting a dynamic orthopedic implant shape from one of the possible shapes, where the dynamic orthopedic implant shape selected satisfies predetermined kinematic and anatomical constraints.

A method of designing an orthopedic implant comprising: (a) iteratively evaluating possible shapes of a dynamic orthopedic implant using actual anatomical shape considerations and kinematic shape considerations; and, (b) selecting a dynamic orthopedic implant shape from one of the possible shapes, where the dynamic orthopedic implant shape selected satisfies predetermined kinematic and anatomical constraints.

A method of designing an orthopedic implant comprising: (a) iteratively evaluating possible shapes of a dynamic orthopedic implant using actual anatomical shape considerations and kinematic shape considerations; and, (b) selecting a dynamic orthopedic implant shape from one of the possible shapes, where the dynamic orthopedic implant shape selected satisfies predetermined kinematic and anatomical constraints.

A digital bone reconstruction method that involves receiving medical image data of a bone; displaying on a user interface the bone image; automatically generating, using a processor, a first virtual 3D surface contour of a reconstructed image of the bone having a first geometry and including a plurality of editable control regions; and adjusting at least one of the editable control regions on the first virtual 3D surface contour based on user input to produce a second virtual 3D surface contour of the reconstructed image of the bone having a second geometry.