An orthopedic implant comprising: (a) a distal femoral component comprising a first condyle bearing surface having a first profile comprising at least three consecutive arcs of curvature; and (b) a proximal tibial component comprising a first condyle bearing surface having a second profile comprising at least three parallel arcs of curvature.

Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a boundary is prepared. A space including the porous CAD volume is populated with unit cells. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. The space is populated with at least one elongated fixation element extending beyond the boundary to produce an interlocking feature enabling assembly or engagement with a mating structure.

Systems and methods for verifying the quality of patient specific implants are disclosed. A system can generate implant data, such as design files or fabrication instructions, for manufacturing the implant. The system can manage access to the implant data based on authentication levels. Based on the determined authentication level of the user requesting access to the implant data, the system can permit the user to access some or all of the implant data. The system can perform a quality check on a manufactured implant by scanning the manufactured implant to identify any errors in the manufactured implant.

A fabrication system and method for prosthetic appliances employs imaging of a contralateral skeletal structure for designing a matched, patient specific replacement appliance based on the patient's own skeletal structure. Many skeletal structures are disposed on opposed sides, i.e. left and right sides. A contralateral bone or skeletal member often accurately depicts the individual bone shape of a particular patient more accurately than a generalized approximation. A scan such as a CT or MRI is segmented to apportion a skeletal member for replacement and reconstructed into a 3D (3 dimensional) model. The 3D model is inverted to define the contralateral side, and augmented for surgical connection features and comparison with an anatomic ideal to mitigate imperfections. 3D printing and/or additive manufacturing techniques are invoked with biocompatible materials to render the replacement prosthetic appliance based on the model.

Methods of making medical devices are described. An example device is an implant used in spaces between vertebrae in a vertebral column of an animal. The example medical device includes a main body that has a lengthwise axis, a proximal end, a distal end, a length that extends from the proximal end to the distal end, an upper wall, a lower wall, a first lateral wall, a second lateral wall, and defines a plurality of pockets, a plurality of pocket supports, an interior chamber, a plurality of windows, and a recess. A pocket support of the plurality of pocket supports is disposed within each pocket of the plurality of pockets. A first mask includes an elongate member and a plurality of projections and is integrally formed with the medical device main body. The mask is used for performing a finishing process on the device and subsequently removed using a tool.

The present disclosure relates to a method for designing an implant for finger bones. In more detail, the present disclosure relates to a method for designing an implant for finger bones, the method including a finger bone image collection step of collecting 3D images of several human finger bones, a finger bone measurement step of measuring the length, cross-sectional width, and thickness of each of the finger bones from the 3D images of the finger bones, and an implant shape derivation step of calculating average values of the lengths, cross-sectional widths, and thicknesses of the finger bones and deriving and storing the shapes of implants for finger bones into a database on the basis of the calculated average values of the cross-sectional widths and thicknesses and shapes of cut surfaces.

Systems, methods, and techniques for customizing connectors for connecting standardized implant components together or to a part of a patient. The connectors are customized based on medical imagery of the patient and/or other patient data and may use additive or subtractive manufacturing techniques. The connectors can be manufactured at the point of use and used with standardized components.

The present disclosure includes fixation devices, such as an orthopedic screw or implant, that comprises one or more porous elements or fenestrations to aid in osteo-integration of the fixation device. The fixation device may be additively manufactured using biocompatible materials such that the solid and porous aspects of the screw are fused together into a single construct. In yet another aspect, the fixation device comprises at least a portion or section incorporating a porous structure, which enables bony ingrowth through the porous section/portion of the screw, and thereby facilitates biocompatibility and improve mechanical characteristics. Methods for using the fixation device are also described herein.

An apparatus and modeling method of the present invention includes the successive steps of generating cartographic data representative of points belonging to a glenoid surface; distinguishing from among the cartographic data a first group of cartographic data corresponding to a first part of the glenoid surface, the first surface part being situated farthest down in the vertical direction in relation to the scapula; calculating from the first group of cartographic data a first ellipsoid portion that coincides substantially with the first surface part; and obtaining a theoretical glenoid surface from the first ellipsoid portion. By virtue of the theoretical glenoid surface obtained by this method, it is possible to assist the surgeon in optimizing the position of implantation of a glenoid component and to produce a glenoid component “made to measure” for the scapula that is to be fitted with a prosthesis.

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.