Methods for growing spinal implants in situ using a surgical additive-manufacturing system. In one aspect, the method includes positioning a dispenser at least partially within an interbody space, between a first patient vertebra and a second patient vertebra. The method includes maneuvering the dispensing component within the space to deposit printing material forming an interbody implant part, positioning the dispensing component adjacent the vertebrae, and maneuvering the dispenser adjacent the vertebrae to deposit printing material on an exterior surface of each vertebrae and in contact with the interbody implant part forming an extrabody implant part connected to the interbody implant part and vertebrae, yielding the spinal implant grown in situ connecting the first vertebra to the second vertebra. The extrabody part can be printed around anchors affixed to the vertebrae, and the anchors may be printed in the process.

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.

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.

Systems and methods for performing surgery based on an analysis of images captured in at least two different planes are disclosed. According to some embodiments, a first X-ray image of a spine in a first plane and a second X-ray image of the spine in a second plane are obtained, and a curve is drawn on the first and second X-ray images so that the curve tracks the vertebral bodies of the spine. The coordinates of the curve in the first and second X-ray images are determined by performing image processing to detect the curve in the X-ray images. A three-dimensional model of the spine is constructed based on the coordinates. The model is analyzed based on medical data relating to the spine and models of other spines to determine parameters of a spinal device. The spinal device is constructed and deployed in the spine based on the parameters.

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 orthopedic device includes a femoral implant having a non-custom internal bone engagement surface. The femoral implant includes at least nine parameters adjusted preoperatively to correspond to a specific patient. The parameters can include patient-specific lengths, such as, for example, medial and lateral condyle widths and notch height, and patient-specific medial and lateral angles.

An orthopedic measurement system is disclosed to measure leg alignment. The measurement system includes a tri-axial gyroscope configured to measure movement of a leg. The gyroscope is coupled to a tibia of the leg. For example, the gyroscope can be placed in an insert or tibial prosthetic component that couples to the tibia. The gyroscope is used to measure alignment relative to the mechanical axis of the leg. The leg alignment measurement is performed by putting the leg through a first leg movement and a second leg movement. The gyroscope outputs angular velocities on the axes the sensor is rotated about. The gyroscope is coupled to a computer that calculates the alignment of the leg relative to the mechanical axis from the gyroscope measurement data.

Various embodiments of implant systems and related apparatus, and methods of operating the same are described herein. In various embodiments, an implant for interfacing with a bone structure includes a web structure, including a space truss, configured to interface with human bone tissue. The space truss includes two or more planar truss units having a plurality of struts joined at nodes. Implants are optimized for the expected stress applied at the bone structure site.

An orthopedic measurement system is disclosed to measure leg alignment. The measurement system includes a tri-axial gyroscope configured to measure movement of a leg. The gyroscope is coupled to a tibia of the leg. For example, the gyroscope can be placed in an insert or tibial prosthetic component that couples to the tibia. The gyroscope is used to measure alignment relative to the mechanical axis of the leg. The leg alignment measurement is performed by putting the leg through a first leg movement and a second leg movement. The gyroscope outputs angular velocities on the axes the sensor is rotated about. The gyroscope is coupled to a computer that calculates the alignment of the leg relative to the mechanical axis from the gyroscope measurement data.

An orthopedic device for implanting between adjacent vertebrae comprising: an arcuate balloon and a hardenable material within said balloon. In some embodiments, the balloon has a footprint that substantially corresponds to a perimeter of a vertebral endplate. An inflatable device is inserted through a cannula into an intervertebral space and oriented so that, upon expansion, a natural angle between vertebrae will be at least partially restored. At least one component selected from the group consisting of a load-bearing component and an osteobiologic component is directed into the inflatable device through a fluid communication means.