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.

An alloprosthetic composite implant comprising includes a structural porous scaffold having a pore density profile corresponding to a density profile of bone to be replaced. A plurality of cells are seeded within pores of the porous scaffold and grown by incubation. The cells may include osteoblasts and/or stem cells to form the structure of the implant, and one or more cartilage layers may be grown on top of the scaffold. The pore density profile of the scaffold may be formed based on one or both of the bone density profile of the bone to be removed, and the bone density profile of the native bone that will be in contact with the alloprosthetic implant. A robot may be employed reo resect the native bone and also to shape the alloprosthetic implant to fit into place in the native bone.

A method of manufacturing a surgical kit for cartilage repair in an articulating surface of a joint, comprising the steps of receiving radiology image data representing three dimensional image of a joint; generating a first three dimensional representation of a first surface of the joint in a trainable image segmentation process dependent on a trained segmentation process control parameter set and said radiology image data; generating a set of data representing a geometrical object based on said first surface, wherein said geometrical object is confined by said first surface; generating control software adapted to control a CAD or CAM system to manufacture a surgical kit for cartilage repair dependent on said set of data representing a geometrical object and on a predetermined model of components of said surgical kit.

A low-profile intercranial device including a low-profile static cranial implant and a functional neurosurgical implant. The low-profile static cranial implant and the functional neurosurgical implant are virtually designed and interdigitated prior to physical assembly of the low-profile intercranial device.

This invention relates to Patient-Specific Templates (PST) which have already been used by implant manufacturers and clinically applied by orthopedic surgeons. This work presents an apparatus comprised of a unit acquiring data from the surface of bones and joints, a computerized unit for surgical planning and a desktop 3D printer for manufacturing PST, which are functionally, physically and electrically connected. The apparatus is compact, portable and suitable for hospital-based or clinic-based service. The data-collection unit has electro-magnetic (EM) device, diagnostic ultrasound machine, laser scanner and a receiver for acquisition of external data. It integrates the data from multiple sources and has sensor fusion ability. The surgical planning unit has specific software program capable of merging the collected data through mathematical model of specific parts of bones, joints and a library of implants and prostheses.

A method of preparing a surgical plan comprises video capturing a range of motion of an anatomic joint of a patient to obtain a range of motion video, registering the range of motion video to two-dimensional images of a skeleton of the patient, identifying potential impingement and stability issues in the anatomic joint based on the range of motion video, templating a prosthetic implant on two-dimensional images of the anatomic joint using the identified potential impingement and stability issues of the anatomic joint to obtain position and orientation data, and electronically saving the position and orientation data of the prosthetic implant for use with a surgical navigation system. A system for planning and performing a surgical procedure comprises a motion capture system, an x-ray system, an electronic modeling system, and a surgical navigation system.

A method for manufacturing an implant including the steps of providing an implant element, the implant element made of a non-metallic material, depositing a thin layer of titanium-based material directly over an outer surface of the implant element, and forming a titanium-based structural body in direct contact with the thin layer by three-dimensional (3D) printing, the structural body being thicker than the thin layer of titanium-based material.

An orbital implant adapted for attachment to the very thin bone at the orbit rim (502), such as the zygomatic and frontal bone margin at the supero-lateral aspect (501) of the orbit (503), for the attachment of an eye prosthesis directly to distal ends of inwardly convergently orientated transdermal abutments. The orbital implant has a baseplate (100) having an orbit radius curvature and an orbit rim curvature and a plurality of microfixation apertures therethrough and the plurality of transdermal abutments are located at an inner edge of the baseplate (100).

A method of manufacturing a surgical implant includes simultaneously forming a first component and a second component of the surgical implant. Formation of the first and second components includes depositing a first quantity of material to a building platform and fusing the first quantity of material to form a first layer of the first and second components. The method of manufacturing also includes depositing a second quantity of material over the first layer of the first and second components and fusing the second quantity of material to form a second layer of the first and second components. The surgical implant is fully assembled upon the completion of the formation of the first and second components.

The interface device includes a first surface that matches the surface morphology of the corresponding artificial disc and a second surface that matches the surface morphology of the corresponding endplate of the vertebrae. The interface device of the present disclosure can be fabricated using the three-dimensional printing technology.