Methods, apparatuses, and systems for customized kit assembly for surgical implants are disclosed. A robotic surgical system designs and customizes a surgical implant and its surgical implant components. The surgical implant and its surgical implant components are assembled into a kit that is customized for a specific patient. The robotic surgical procedure using the kit can additionally select from available generic, off-the-shelf surgical implant components or customized surgical implant components.

A method and system for creating a custom-fit orthopedic cast comprises obtaining at least one measurements taken from at least one image of a body part, selecting a template cast, modifying the template cast according to the measurements taken from the at least one image to generate a custom cast model and rendering a custom cast based on the custom cast model.

A system 100 or designing a surgical kit 700 for articulating surface repair in an anatomical joint of a patient is provided, which comprises at least one processor 120 configured to: determine damage to the anatomical joint; select, from a predefined set of implants having varying dimensions, the implant 300 that is the best fit for repairing the determined damage; select, from a predefined set of insert tools, the insert tool 720 corresponding to the selected implant 300; and design a contact surface 540 of a guide tool 500 to have a shape and contour that is designed to correspond to and to fit the contour of a predetermined area. This enables the use of standardized implants 300 that can be manufactured batch-wise, while still using an individualized guide tool 500 to ensure correct positioning of the implant 300. This helps ensuring that the implant will be positioned in the exact location of the determined damage.

An acetabular shell component includes a solid substrate, a porous outer layer coupled to the solid substrate, a porous inner layer coupled to the solid substrate, and an inner bearing coupled to the porous inner layer. One or more adjuncts extend outward from the porous outer layer. Each adjunct includes an outer surface that defines a customized patient-specific negative contour shaped to conform to a positive contour of a patient's bone. A method for manufacturing the acetabular shell component using an additive manufacturing process is also disclosed.

The production of bioceramic powders and bioceramic implants are described and an additive manufactured implant used for tissue reconstruction and a method for manufacturing the implant are disclosed. The implant may be fabricated at least in part from suitable bioceramic powders produced using tailored mineral compositions tailored to the unique material properties of the tissue being replaced. The implants may be tailored to a three-dimensional shape and mechanical properties of the tissue defect designed to be replaced by surgical implantation of the device. Native tissue repair and regeneration at the site of implantation are also provided.

A method of preparing an interpositional implant suitable for a knee. The method includes determining a three-dimensional shape of a tibial surface of the knee. An implant is produced having a superior surface and an inferior surface, with the superior surface adapted to be positioned against a femoral condyle of the knee, and the inferior surface adapted to be positioned upon the tibial surface of the knee. The inferior surface conforms to the three-dimensional shape of the tibial surface. The implant may be inserted into the knee without making surgical cuts on the tibial surface. The tibial surface may include cartilage, or cartilage and bone.

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 cutting guide for guiding a cut in a radius, the radius being adjacent to an ulna, the cutting guide comprising: a cut guiding portion, an opposed ulnar mounting portion and a linking portion extending therebetween; the cutting guide being delimited by a cutting guide peripheral surface defining a bone facing portion, the bone facing portion being contoured to match the shape of the radius and ulna.

A talar implant having at least one body section, at least one mesh section and at least one solid section extending down from the body section. The solid section having at least one point end. Further disclosed is a kit for inserting a talar implant including at least one tibial guide, at least one talar guide, and at least one impactor for inserting the talar implant into a talus. In addition, a method for implanting a talus implant is disclosed. The method can include identifying a damaged area on a talus, projecting a missing damaged area on a contralateral joint and printing an implant based upon a mirror image of a portion of the contralateral joint. The method can include applying at least one guide, removing at least a portion of a damaged region of the talus, inserting the talar implant and setting the talar implant in the talus.

There is disclosed a talus implant comprising a base having at least one hole and at least one pin. There is also a top comprising at least one hole and at least one pin, wherein the top is configured to be inserted into the base. At least one embodiment comprises a tibial implant comprising at least one post and at least one base coupled to the at least one post. Additionally, there is at least one pad coupled to the at least one base, wherein the at least one pad is selectively insertable into and removable from the at least one base. A method for fabricating a talus and tibial implant is disclosed and also a method for inserting a talus implant and a tibial implant into a patient having a damaged talus joint.