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.

A computing system according to an embodiment includes at least one processor and at least one memory comprising a plurality of instructions stored thereon that, in response to execution by the at least one processor, causes the computing system to determine a plurality of implant size predictions with associated confidence levels based on one or more patient or surgical parameters, wherein each of the implant size predictions identifies a confidence level that a prospective implant of a corresponding size will fit a patient, determine whether a combined confidence level determined based on a subset of the plurality of associated confidence levels is at least a threshold value, and recommend, in response to a determination that the combined confidence level is not at least the threshold value, incorporation of at least one of an additional implant size prediction of the plurality of implant size predictions in the subset or digital templating data to improve an accuracy of an implant size estimation.

An example method includes obtaining, a virtual model of a portion of an anatomy of a patient obtained from a virtual surgical plan for an orthopedic joint repair surgical procedure to attach a prosthetic to the anatomy; identifying, based on data obtained by one or more sensors, positions of one or more physical markers positioned relative to the anatomy of the patient; and registering, based on the identified positions, the virtual model of the portion of the anatomy with a corresponding observed portion of the anatomy.

A system and method for providing a surgical instrument having a shaft with a proximal end, a distal end, a longitudinal axis, and a central lumen extending therethrough; and a tapered head at the distal end. The tapered head has a plurality of longitudinal channels, a plurality of threaded sections, and a plurality of lateral lumens. The plurality of longitudinal channels may form a plurality of flutes configured to cut bone, tissue, or both.

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.

Disclosed are systems, methods, and techniques for registering a HMD coordinate system of a head-mounted display (HMD) and a localizer coordinate system of a surgical navigation localizer. A camera of the HMD captures at least one image of a registration device having a registration coordinate system and a plurality of registration markers. The registration markers are analyzed in the at least one image to determine a pose of the HMD coordinate system relative to the registration coordinate system. One or more position sensors comprised in the localizer detect a plurality of tracking markers comprised in the registration device to determine a pose of the registration coordinate system relative to the localizer coordinate system. The HMD coordinate system and the localizer coordinate system are registered using the registration device, wherein positions of the registration markers are known with respect to positions of the tracking markers in the registration coordinate system.

A method for creating a patient-specific surgical plan includes receiving one or more pre-operative images of a patient having one or more infirmities affecting one or more anatomical joints. three-dimensional anatomical model of the one or more anatomical joints is created based on the one or more pre-operative images. One or more transfer functions and the three-dimensional anatomical model are used to identify a patient-specific implantation geometry that corrects the one or more infirmities. The transfer functions model performance of the one or more anatomical joints as a function of anatomical geometry and anatomical implantation features. surgical plan comprising the patient-specific implantation geometry may then be displayed.

A number of improvements are provided relating to computer aided surgery. The improvement relates to both the methods used during computer aided surgery and the devices used during such procedures. Some of the improvement relate to controlling the selection of which data to display during a procedure and/or how the data is displayed to aid the surgeon. Other improvements relate to the structure of the tools used during a procedure and how the tools can be controlled automatically to improve the efficiency of the procedure. Still other improvements relate to methods of providing feedback during a procedure to improve either the efficiency or quality, or both, for a procedure.

The disclosure describes examples of machine-learned model based techniques. A computing system may obtain patient characteristics of a patient and implant characteristics of an implant. The computing system may determine information indicative of an operational duration of the implant based on the patient characteristics and the implant characteristics and output the information indicative of the operational duration of the implant. In some examples, one or more processors may be configured to receive, with a machine-learned model of the computing system, implant characteristics of an implant to be manufactured, apply model parameters of the machine-learned model to the implant characteristics, determine information indicative of dimensions of the implant to be manufactured based on the applying of the model parameters of the machine-learned model, and output the information indicative of the dimensions of the implant to be manufactured.

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.