Femoral Registration Tool Geometry for Precise Robotic Alignment

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Solution Overview

Problem

The existing methods for surgical registration in robotic-assisted orthopedic joint replacement surgery lack efficiency and effectiveness, necessitating improved tools and systems to enhance the accuracy and precision of registering robotic systems to patient anatomy during preoperative planning.

Innovation Solution

A surgical registration tool featuring a bone engagement structure with distal, posterior, and side condyle abutment structures, along with an anterior shaft abutment, coupled to a handle and tracker array, allows for precise registration by contacting specific anatomical points on the femur, such as the condyles and shaft, and includes adjustable components to accommodate varying bone sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional surgical registration methods are used, then the registration process can be completed, but the accuracy and precision of registering robotic systems to patient anatomy is insufficient

Engineering Contradiction:

Improveregistration accuracyVSAvoideffectiveness of registration

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The registration tool is segmented into multiple specialized abutment structures (distal condyle abutment, posterior condyle abutment, side condyle abutment, and anterior shaft abutment), each designed to contact specific anatomical landmarks on the femur. This segmentation allows each component to precisely engage with its corresponding anatomical feature, thereby improving overall registration accuracy and reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each abutment structure possesses locally optimized geometric properties tailored to its specific anatomical contact point. The distal condyle abutment features a curved surface matching the condyle geometry, while the posterior condyle abutment has a planar surface for flat contact. These localized quality adjustments ensure optimal contact and measurement precision at each registration point.

Inventive Principle:

Principle #3Local quality

2Measurement precision

If multiple abutment structures are added to improve registration accuracy, then the precision increases, but the device complexity increases

Engineering Contradiction:

Improveregistration precisionVSAvoidtool structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Multiple abutment structures that would traditionally require separate tools or multiple registration steps are merged into a single integrated registration tool. The distal condyle abutment, posterior condyle abutment, side condyle abutment, and anterior shaft abutment are all combined in one device, allowing simultaneous engagement with multiple anatomical landmarks and simplifying the registration process despite the increased functional complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The registration tool is designed as a universal device capable of performing multiple registration functions across different anatomical regions of the femur. Each abutment structure serves a specific function, but collectively they provide a comprehensive registration solution that eliminates the need for multiple specialized tools, thereby managing device complexity while maintaining high precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If adjustable components are included to accommodate varying bone sizes, then the adaptability increases, but the device complexity increases

Engineering Contradiction:

Improveaccommodation of varying bone sizesVSAvoidadjustable mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The registration tool incorporates adjustable abutment structures that can dynamically adapt to different femoral anatomies. The adjustable components allow the distance and positioning between abutments to be modified based on patient-specific bone dimensions, enabling the same tool to accurately register across a range of bone sizes without requiring multiple fixed-size tools.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12465427B2Surgical registration tools, systems, and methods of use in computer-assisted surgery

Publication Date: 2025.11.11 MAKO SURGICAL CORP

AI summary

A surgical registration tool including a bone engagement structure comprising a distal condyle abutment structure, at least one posterior condyle abutment structure, a side condyle abutment structure, and an anterior shaft abutment structure. The distal condyle abutment structure includes a distal planar surface. The at least one posterior condyle abutment structure includes at least one planar surface extending distally from the distal planar surface and positioned perpendicular to the distal planar surface. The side condyle abutment structure includes a planar surface extending distally from the distal planar surface and positioned perpendicular to the distal planar surface and the at least one planar surface. The anterior shaft abutment structure extends distally from the distal planar surface and terminates at a distal tip. The registration tool also includes a handle coupled to the engagement structure and extending proximally therefrom, and a tracker array configured to couple to the handle.