Methods and apparatus are provided for forming a patient-specific surgical implant based on mold system. The apparatus comprises a forming tool and a mold that may be generated using imaging and processing techniques and rapid prototyping methods. The mold apparatus includes at least two non-adjacent surface features for securing an implant forming material (such as a titanium mesh) during the forming process, enabling the implant forming material to be stretched beyond its elastic and thus permanently deformed with the correct patient-specific curvature. The implant may include one or more anatomic surface features for guidance and registration when transferring the implant to a patient.

Systems, devices, and methods are provided for orthopedic implants. The implants may include a base member, such as an acetabular shell or an augment, that is configured to couple with an augment, flange cup, mounting member, or any other suitable orthopedic attachment. Mounting members include, for example, flanges, blades, hooks, and plates. In some embodiments, the orthopedic attachments may be adjustably positionable about the base member or other attachments, thereby providing modularity for assembling and implanting the device, and various securing and/or locking mechanisms may be used between the components of the implant.

Provided is a method for forming an implant with an autonomous manufacturing device. The method includes accessing a first computer-readable reconstruction of a being's anatomy; accessing a second computer-readable reconstruction of an implant; accessing a third computer-readable reconstruction comprising the first computer-readable reconstruction superimposed with the second computer readable reconstruction; generating at least one computer-readable trace from a point cloud; and forming an implant with an autonomous manufacturing device, wherein the autonomous manufacturing device forms the implant into a shape defined by at least one dimension of the computer-readable trace.

Systems, devices, and methods are provided for orthopedic implants. The implants may include a base member, such as an acetabular shell or an augment, that is configured to couple with an augment, flange cup, mounting member, or any other suitable orthopedic attachment.

Embodiments of the present disclosure relate generally to an orbital floor implant (10). One embodiment provides an implant with a first surface that is a fully porous, bone-side layer (16) and a second surface that is a non-porous, orbital content-side layer (18). The implant material itself may be polymeric material throughout, without the need for an embedded mesh or other support matrix. The implant is provided in a pre-shaped configuration and is of a material that allows it to be bent for shaping purposes. An extending tab (12) with eyelet portion/opening (14) can enhance securement options to a patient's bone.

Methods, systems, and devices for treating osteochondral defects (OCDs) are disclosed. The disclosed methods and systems include collecting joint surface data using image-free methods, generating a three-dimensional (3D) healthy bone model based on the joint surface data and a database of healthy bone anatomies, defining the OCD boundary on the joint, generating a 3D implant model based on the 3D healthy bone model and the OCD boundary, manufacturing an implant based on the 3D implant model, generating an implantation plan, the resected cavity on the joint. The implant includes a 3D-printed titanium alloy substrate having a first and second porous layer separated by a nonporous layer. A polymer material is over-molded onto the second porous layer and treated to exhibit properties that mimic cartilage, while the first porous layer allows the implant to fuse to patient bone.

A bone graft implant and methods of using the same are provided herein.

A method of replacing a portion of a cranium with a hard tissue implant can include resecting a first portion of the cranium to define a first margin region. The first portion of the cranium can be analyzed to determine if the first margin region is free of cancerous cells. A second portion of the cranium can be resected to define a second margin region that is larger than the first margin region when the first margin region is not free of cancerous cells. An outer implant can be secured to the cranium at the second margin region. An inner implant can be secured to the outer implant.

A system and computer-implemented method for manufacturing an orthopedic implant involves segmenting features in an image of anatomy. Anatomic elements can be isolated. Spatial relationships between the isolated anatomic elements can be manipulated. Negative space between anatomic elements is mapped before and/or after manipulating the spatial relationships. At least a portion of the negative space can be filled with a virtual implant. The virtual implant can be used to design and manufacture a physical implant.

A method for performing a cranioplasty includes the steps of prefabricating a sonolucent craniofacial implant based upon information generated by preoperative scans, creating a cranial, craniofacial, and/or facial defect, and attaching the craniofacial implant to the cranial, craniofacial, and/or facial defect. The craniofacial implant is composed of a material that is sonolucent and exhibits attenuation of less than 6 dB/cm.