Methods and systems of augmenting an implant intraoperatively and preparing a cone for revision surgical procedure are disclosed. A system includes a cutting device, a tracking and navigation system and a cutting system in operable communication with the cutting device and the tracking and navigation system. The cutting device includes a communication system, a cutting element, and a plurality of optical trackers. The tracking and navigation system is configured to detect a location of optical trackers. The control system is configured to cause the tracking and navigation system to detect the location of the cutting device, determine a revised shape for an implant cavity, cause the cutting device to cut the implant cavity to the revised shape, select a shape for a cone to be placed in the revised implant cavity, and machine the cone to the selected shape.

A medical implant for cartilage and/or bone repair at an articulating surface of a joint is provided. The implant includes a contoured implant body and at least one extending post. The implant body has an articulating surface configured to face the articulating part of the joint and a bone contact surface configured to face the bone structure of a joint, where the articulating and bone contact surfaces face mutually opposite directions and the bone contact surface is provided with the extending post. A cartilage contact surface connects the articulating and the bone contact surfaces and is configured to contact the cartilage surrounding the implant body in a joint. The articulating surface has a layer that is formed of titanium nitride (TiN) as the wear-resistant material. The cartilage contact surface has a coating that is formed of a material having chondrointegration properties.

Systems and methods are provided for implant design and manufacturing to optimize the bone-implant interface. The implant design and methodology may include accounting for the anatomy of a bone of a subject to address optimize the bone-implant interface considerations for the subject. Implants or components may be asymmetrically designed to better match the associated anatomy as well as optimize the bone-implant interface, such as by quantifying bone density and matching material properties of the implant or coatings of the implant. Information derived from the methodology can be used to guide the design of the implant resulting in an asymmetric design that optimizes the bone-implant interface.

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.

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.

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.

In various embodiments, an implant for interfacing with a bone structure includes a web structure including a space truss. The space truss includes two or more planar truss units having a plurality of struts joined at nodes and the web structure is configured to interface with human bone tissue. In some embodiments, a method is provided that includes accessing an intersomatic space and inserting an implant into the intersomatic space. The implant includes a web structure including a space truss. The space truss includes two or more planar truss units having a plurality of struts joined at nodes and the web structure is configured to interface with human bone tissue.

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.