Medical device for surgical navigation system and corresponding method of manufacturing

1. A device for a surgical navigation system, comprising:

a frame member having an attachment location;

a rigid mounting device disposed in the attachment location; and

wherein the frame member comprises an upper portion connected to a lower portion via a bent portion,

wherein the lower portion comprises a plurality of mounting posts each having a top surface,

wherein a centerline extends through the rigid mounting device such that a horizontal plane running through the centerline aligns with each of the top surfaces,

wherein marker elements are mounted to the plurality of mounting posts such that upon mounting, a centerline of the marker elements aligns with the centerline extending through the rigid mounting device.

2. The device of claim 1 , wherein the marker elements are spherical.

3. The device of claim 2 , wherein the marker elements are light-reflecting spherical markers.

4. The device of claim 1 , wherein the frame member is plastic.

5. The device of claim 4 , wherein the plastic is selected from one of a polycarbonate, polyetheretherketone, and a polyetherimide material.

6. The device of claim 1 , wherein the mounting device is metal.

7. The device of claim 6 , wherein the metal is selected from one of aluminum, anodized aluminum, and stainless steel.

8. The device of claim 1 , wherein the lower portion extends into a flared extension portion.

9. The device of claim 8 , wherein the flared extension portion comprises an asymmetric configuration.

10. The device of claim 9 , wherein the asymmetric configuration comprises an astroid design having four cusps.

11. The device of claim 10 , wherein one of the plurality of mounting posts is disposed at endpoints of the astroid design.

12. The device of claim 11 , wherein the astroid design comprises three endpoints having a respective one of the plurality of mounting posts attached thereto.

13. The device of claim 1 , wherein the device comprises indicia disposed on the frame member.

14. A method of manufacturing a device comprising:

(a) configuring a frame member to form an upper portion and a lower portion connected by a bent portion;

(b) mounting a rigid mounting device to an attachment location of the upper portion, wherein a centerline extends through the rigid mounting device;

(c) connecting a plurality of mounting posts on the lower portion, wherein each plurality of mounting posts has a top surface, wherein the bent portion is configured such that a horizontal plane running through the centerline aligns with each top surface of the plurality of mounting posts; and

(d) mounting a marker element on each mounting post such that a centerline of each mounted marker element aligns with the top surface of the mounting post.

15. The method of claim 14 , further comprising:

(e) extending the lower portion into a flared extension portion.

16. The method of claim 15 , wherein the flared extension portion comprises an asymmetric configuration.

17. The method of claim 16 , the asymmetric configuration comprises an astroid design having four cusps.

18. The method of claim 17 , wherein one of the plurality of mounting posts is disposed at endpoints of the astroid design.

19. A method of manufacturing a medical device comprising:

(a) configuring a frame member to form an upper portion and a lower portion connected by a bent portion;

(b) mounting a rigid mounting device to an attachment location of the upper portion, wherein a centerline extends through the rigid mounting device; and

(c) mounting marker elements on the frame member, wherein the bent portion is configured such that a horizontal plane running through the centerline aligns with a centerline of each mounted marker element.

20. The method of claim 19 , further comprising:

(d) extending the lower portion into a flared extension portion.

21. The method of claim 20 , wherein the flared extension portion comprises an asymmetric configuration.

22. The method of claim 21 , the asymmetric configuration comprises an astroid design having four cusps.

23. The method of claim 22 , wherein the marker elements are mounted to a plurality of mounting posts disposed at endpoints of the astroid design.

24. A device for a surgical navigation system, comprising:

a frame member having an attachment location; and

a rigid mounting device disposed in the attachment location,

wherein a centerline extends through the rigid mounting device,

wherein the frame member comprises an upper portion connected to a lower portion via a bent portion,

wherein the lower portion comprises a plurality of mounting posts,

wherein marker elements are mounted to the plurality of mounting posts such that upon mounting, a centerline of the marker elements aligns with the centerline extending through the rigid mounting device.

25. The device of claim 24 , wherein each of the plurality of mounting posts has a top surface, wherein a horizontal plane running through the centerline extending through the rigid mounting device aligns with each of the top surfaces.

26. The device of claim 24 , wherein the lower portion extends into a flared extension portion.

27. The device of claim 26 , wherein the flared extension portion comprises an asymmetric configuration.

28. The device of claim 27 , wherein the asymmetric configuration comprises an astroid design having four cusps.

29. The device of claim 28 , wherein one of the plurality of mounting posts is disposed at endpoints of the astroid design.

30. The device of claim 29 , wherein the astroid design comprises three endpoints having a respective one of the plurality of mounting posts attached thereto.