Implant with patient-specific porous structure
View Patent ↗A method of manufacturing a joint implant for a joint of a specific patient includes obtaining a three-dimensional image of a bone of the joint of the specific patient from medical imaging scans of the bone of the patient and determining on the three-dimensional image a resection plane for contacting a corresponding planar surface of the joint implant for the specific patient. The method includes determining a three-dimensional image of a porous structure of a bone layer along the resection plane from the medical imaging scans of the patient. The joint implant is manufactured with a layer of a patient-specific porous construct attached to the planar surface of the joint implant. The layer of the patient-specific porous construct substantially replicates the porous structure of the bone layer of the specific patient.
1. A method of manufacturing a joint implant for a joint of a specific patient comprising:
obtaining a three-dimensional image of a bone of the joint of the specific patient from medical imaging scans of the bone of the patient;
determining on the three-dimensional image a resection plane for contacting a corresponding planar surface of the joint implant for the specific patient;
determining a three-dimensional image of a porous structure of a bone layer along the resection plane from the medical imaging scans of the patient; and
manufacturing the joint implant with a layer of a patient-specific porous construct attached to the planar surface of the joint implant, the layer of the patient-specific porous construct being an inverse of the porous structure of the bone layer of the specific patient, such that the patient-specific porous construct mirrors the porous structure of the bone layer along the resection plane.
2. The method of claim 1 , wherein the joint implant is a femoral knee implant.
3. The method of claim 2 , wherein the planar surface of the joint implant is one of posterior, posterior chamfer, distal, anterior chamfer and anterior flange surface and wherein the layer of a patient-specific porous construct includes a corresponding surface.
4. The method of claim 2 , wherein the planar surface of the joint implant includes posterior, posterior chamfer, distal, anterior chamfer and anterior flange surfaces and wherein the layer of a patient-specific porous construct includes corresponding surfaces.
5. The method of claim 1 , wherein the porous construct includes porous metal.
6. The method of claim 1 , wherein the joint implant is a tibial knee implant.
7. The method of claim 6 , wherein the tibial knee implant is a tibial tray and the porous construct is attached to a distal surface of the tibial tray.
8. The method of claim 7 , wherein the tibial tray includes a plurality of anchoring members extending from the distal surface.
9. The method of claim 8 , wherein the porous construct excludes areas corresponding to footprints of the plurality of the anchoring members.
10. The method of claim 1 , further comprising manufacturing the patient-specific construct using additive manufacturing.
11. The method of claim 1 , wherein the resolution of the medical imaging scans is of the order of a few microns for voxel size.
12. The method of claim 1 , wherein the resolution of the medical imaging scans is about 20 microns of voxel size.
13. A method of manufacturing a joint implant for a joint of a specific patient comprising:
obtaining a three-dimensional image of a distal femoral bone of a joint of the specific patient from medical imaging scans of the distal femoral bone of the patient;
determining on the three-dimensional image a plurality of resection planes for contacting corresponding planar surfaces of an implant core of the joint implant for the specific patient;
determining a three-dimensional image of a porous structure of a bone layer along each of the corresponding resection planes from the medical imaging scans of the un-resected femoral bone of the patient; and
manufacturing the joint implant with a plurality of layers of patient-specific porous constructs attached to the corresponding planar surfaces of the joint implant, each layer of the patient-specific porous construct being an inverse of the porous structure of the corresponding bone layer of the specific patient, such that each layer of the patient-specific porous construct mirrors the porous structure of the corresponding bone layer along the resection plane.
14. The method of claim 13 , wherein the plurality of planar surfaces includes five surfaces.
15. The method of claim 13 , wherein the plurality of planar surfaces includes posterior, anterior and distal surfaces.
16. The method of claim 15 , wherein the plurality of planar surfaces includes posterior chamfer and anterior chamfer surfaces.
17. The method of claim 13 , wherein the implant core includes non-porous material.
18. The method of claim 13 , wherein the implant core includes an exterior articulating surface.
19. The method of claim 13 , wherein the porous structure is determined from medical imaging scans with resolution of a few microns for voxel size.
20. A method of manufacturing a joint implant for a joint of a specific patient comprising:
obtaining a three-dimensional image of a tibial bone of the joint of the specific patient from medical imaging scans of the tibial bone of the patient;
determining on the three-dimensional image a resection plane for contacting a corresponding planar surface of the joint implant for the specific patient;
determining a three-dimensional image of a porous structure of a tibial bone layer along the resection plane from the medical imaging scans of the patient; and
manufacturing the joint implant with a layer of a patient-specific porous construct attached to the planar surface of the joint implant, the layer of the patient-specific porous construct being an inverse of the porous structure of the tibial bone layer of the specific patient, such that the patient-specific porous construct mirrors the porous structure of the tibial bone layer along the resection plane.
21. The method of claim 20 , wherein the porous structure is determined from medical imaging scans with resolution of a few microns for voxel size.
22. The method of claim 1 , wherein the layer of the patient-specific porous construct being the inverse of the porous structure of the bone layer of the specific patient provides a seamless continuation of the porous structure of the bone along surfaces of contact between the implant and the bone.
23. The method of claim 13 , wherein each layer of the patient-specific porous construct being the inverse of the porous structure of the corresponding bone layer of the specific patient provides a seamless continuation of the porous structure of the bone along surfaces of contact between the implant and the bone.
24. The method of claim 20 , wherein the layer of the patient-specific porous construct being the inverse of the porous structure of the corresponding tibial bone layer of the specific patient provides a seamless continuation of the porous structure of the bone along surfaces of contact between the implant and the bone.