An orthopedic implant manufacturing method. The method includes preparing a pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient's joint indicating at least one resection plane, communicating the surgical plan to a surgeon of the patient, and receiving approval of the surgical plan and the resection plane by the surgeon. The method also includes providing automated osteophyte/protrusion removal control for surgeon manipulation, receiving a modified three-dimensional image of a patient's joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from the surgeon, and requesting manufacture of the selected orthopedic implant.

An implant for therapeutically separating bones of a joint has two endplates each having an opening through the endplate, and at least one ramped surface on a side opposite a bone engaging side. A frame is slideably connected to the endplates to enable the endplates to move relative to each other at an angle with respect to the longitudinal axis of the implant, in sliding connection with the frame. An actuator screw is rotatably connected to the frame. A carriage forms an open area aligned with the openings in the endplates. The openings in the endplates pass through the carriage to form an unimpeded passage from bone to bone of the joint. The carriage has ramps which mate with the ramped surfaces of the endplates, wherein when the carriage is moved by rotation of the actuator screw, the endplates move closer or farther apart.

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.

An orthopedic prosthesis for stimulating bone growth may include a substrate having at least one bone-facing surface and at least one internal surface, at least one piezoelectric nanostructure coupled to the at least one bone-facing surface of the substrate, at least one charge storing material placed within the orthopedic prosthesis proximate the at least one internal surface, and an interconnect in electrical communication with the at least one piezoelectric nanostructure and the charge storing material. The at least one piezoelectric nanostructure may be configured to generate an electric charge in response to at least one mechanical force applied to the at least one piezoelectric nanostructure and the interconnect may be configured to transfer the electric charge to the at least one charge storing material to promote bone in-growth within the orthopedic prosthesis and/or on the at least one bone-facing surface.

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.

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.

An implant for therapeutically separating bones of a joint has two endplates each having an opening through the endplate, and at least one ramped surface on a side opposite a bone engaging side. A frame is slideably connected to the endplates to enable the endplates to move relative to each other at an angle with respect to the longitudinal axis of the implant, in sliding connection with the frame. An actuator screw is rotatably connected to the frame. A carriage forms an open area aligned with the openings in the endplates. The openings in the endplates pass through the carriage to form an unimpeded passage from bone to bone of the joint. The carriage has ramps which mate with the ramped surfaces of the endplates, wherein when the carriage is moved by rotation of the actuator screw, the endplates move closer or farther apart.

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.

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.