A method for forming a prosthesis comprising a bone-like portion and a cartilage-like portion can comprise additively manufacturing a first positive mold in accordance with a portion of a first three-dimensional model of a portion of a bone. A first negative mold can be formed from the first positive mold. The bone-like portion can be created within the first negative mold. A second positive mold of the bone and a cartilage can be additively manufactured from a second three-dimensional model. A portion of the second three-dimensional model can correspond to a portion of the first three-dimensional model. A second negative mold can be formed from the second positive mold. The bone-like portion can be positioned in the second negative mold so that the second negative mold and the bone-like portion can define a cartilage space that can be filled with a material to form the cartilage-like portion of the prosthesis.

A sacroiliac joint implant is formed from a web structure having a space truss with two or more planar truss units having a plurality of struts joined at nodes. The web structure is configured for fusion of a sacroiliac joint.

The present invention includes a method for generating a three-dimensional model of a bone. The method may further include 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 may includes excavating the bone with an autonomous extremity excavator utilizing the cut plan generated by a processor. In a further arrangement, the method may include 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 medical implant which comprises a porous lattice is fabricated with additive manufacturing techniques such as direct metal laser sintering. A CAD model of the porous lattice is created by defining a trimming volume and merging some lattice elements with adjacent solid substrate.

A stem portion is formed such that when implanted in a scapula the stem portion includes three cross-sections parallel to a medial lateral plane. The middle cross-section has a length in the medial-lateral direction which is shorter than the lengths of the other two cross-sections in the medial lateral direction.

Methods and devices for correcting wear pattern defects in joints. The methods and devices described herein allow for the restoration of correcting abnormal biomechanical loading conditions in a joint brought on by wear pattern defects, and also can, in embodiments, permit correction of proper kinematic movement.

A medical imaging device takes one or more images of the local anatomy of a patient undergoing a surgical procedure. A surface model generator receives the one or more images and generates a 3-D surface model of the patient's anatomy. A fabrication device utilizes the 3-D surface model to fabricate a template custom designed to match the surface of the patient's anatomy. Attached to the template is a directional guide vane. The fabrication device is configured to create a template and directional guide vane such that, when the template is fitted to the patient's anatomy, the directional guide vane points along a predefined orientation relative to the patient's anatomy. A physician uses the directional guide vane as a visual guide or cue for installing an implantable prosthetic component during a surgical procedure.

An additive-manufacturing system for printing spinal implants in-situ, within a patient, is disclosed. The system may include a robotic subsystem having scanning and imaging equipment and an armature including at least one dispensing nozzle and a controller apparatus having a processor and a non-transitory computer-readable medium. The controller may control the scanning and imaging equipment to determine a target alignment of a patients spine, develop an in-situ-printing plan including an in-situ material selection plan based on the target alignment of the patients spine, an interbody access space, and a disc space between adjacent vertebra of the patients spine, and execute the in-situ-printing plan. The controller may further control the armature to dispense at least one material chosen from a rigid material and a pliable material to form at least one motion-sparing implant.

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.

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.