Customized Arthroplasty Jigs Using 3D Surface Scanning
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Solution Overview
Problem
Current arthroplasty procedures face challenges in accurately aligning implants due to variations in human anatomy, leading to inconsistent surgical outcomes, longer surgery times, and higher costs, particularly in total knee arthroplasty (TKA) procedures, where traditional methods rely on two-dimensional imaging and may require extensive incisions and expensive navigation systems.
Innovation Solution
The development of customized arthroplasty jigs formed from near-shape blanks using preoperative planning and machining, combined with surface-matching devices featuring pins and blocks, to precisely align and position implants based on three-dimensional anatomical models, reducing the need for extensive incisions and enhancing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional two-dimensional imaging and landmark-based techniques are used for preoperative planning, then the surgical procedure can be performed with standard equipment, but the alignment accuracy of implants is insufficient due to soft tissue obscuring landmarks and anatomical variations
Solution Approach 1:
The patent transitions from two-dimensional imaging to three-dimensional surface scanning and modeling. The surface-matching device uses multiple pins extending at different angles to capture three-dimensional anatomical surface features, creating a 3D digital model that eliminates soft tissue obscuring issues and provides precise alignment data without requiring complex navigation systems.
Solution Approach 2:
The patent creates a digital copy of the patient's anatomical surface through non-contact optical scanning. The 3D surface model serves as a digital replica that can be used for virtual implant positioning and alignment planning, eliminating the need to physically access obscured landmarks during surgery.
2Manufacturing precision
If robot-assisted TKA procedures are used to achieve accurate alignment, then implant positioning precision is improved, but the surgery time increases and capital equipment cost becomes relatively high
Solution Approach 1:
The patent performs surface scanning and 3D modeling in the preoperative phase, allowing implant positioning to be determined before surgery. The custom cutting guide is manufactured in advance based on the 3D model, eliminating the need for complex intraoperative robotic positioning systems and reducing surgery time while maintaining high precision.
Solution Approach 2:
The patent uses disposable custom cutting guides made from biocompatible polymer materials. These single-use guides are manufactured specifically for each patient based on their 3D surface model, providing accurate alignment without requiring expensive reusable robotic systems or navigation equipment.
3Measurement precision
If imageless navigation systems are employed during surgery for intraoperative planning, then implant alignment can be enhanced, but the capital equipment cost and surgery duration increase
Solution Approach 1:
The patent performs all measurement and planning activities in the preoperative phase using portable surface scanners. The 3D surface model and implant positioning plan are determined before surgery, eliminating the need for complex intraoperative navigation systems and reducing both equipment requirements and surgery time.
Solution Approach 2:
The patent replaces complex mechanical navigation systems with a combination of optical surface scanning and computer-aided design. The custom cutting guide translates the digital alignment plan into physical guidance during surgery, eliminating the need for expensive navigation hardware and software infrastructure.
4Ease of manufacture
If landmark-based techniques are used for implant positioning, then the procedure can be performed with simple equipment, but the consistency of surgical outcomes varies significantly due to anatomical variations and soft tissue coverage
Solution Approach 1:
The patent focuses on capturing and utilizing specific local surface features of the bone that are visible through the incision. The surface-matching device identifies and measures these local anatomical characteristics to determine implant positioning, providing consistent results that account for individual anatomical variations without requiring complex equipment.
Solution Approach 2:
The patent changes the measurement parameters from traditional 2D landmark coordinates to 3D surface geometry data. By capturing surface elevation, curvature, and spatial relationships in three dimensions, the system achieves consistent implant positioning that accounts for anatomical variations while maintaining procedural simplicity.
Data Source
AI summary
Arthroplasty jigs, arthroplasty jig blanks, and related methods and devices are disclosed. Some variations of the methods comprise forming an arthroplasty jig from a near-shape arthroplasty jig blank, where the near-shape arthroplasty jig blank has at least one feature specific to a target site to be matched by the arthroplasty jig. Certain of the methods comprise forming an arthroplasty jig having a first configuration from a near-shape arthroplasty jig blank having a second configuration approximating the first configuration. Some of the methods comprise forming a near-shape arthroplasty jig blank, where the near-shape arthroplasty jig blank is configured to be formed into an arthroplasty jig, and the near-shape arthroplasty jig blank has at least one feature specific to a target site to be matched by the arthroplasty jig.