3D PRINTING SURGICAL REPAIR SYSTEMS
Various embodiments of methods of making one or more components of surgical repair systems, including embodiments employing 3D printing of one or more components, are disclosed. In various embodiments, multiple surgical repair system components may be based, at least in part, on a patient-adapted surface model.
1 . A method of making a surgical repair system for a patient, the method comprising:
receiving patient-specific data regarding the patient;
deriving a patient-adapted surface model of planned resected bone from the patient-specific data;
deriving a patient-adapted surface model of a joint-facing surface from the patient-specific data;
providing a negative form of the resected-bone surface model and a positive and/or corrected form of the joint-facing surface model to a 3D printing apparatus;
printing a patient-adapted implant component that substantially includes the negative form of the patient-adapted resected-bone surface and the positive and/or corrected form of the patient-adapted joint-facing surface; and
removing one or more support structures from the implant component utilizing a form of the joint-facing surface model and/or a form of the resected-bone surface model.
2 . The method of claim 1 , wherein the removing one or more support structures from the implant component comprises utilizing the negative form of the resected-bone surface model.
3 . The method of claim 1 , wherein the removing one or more support structures from the implant component comprises utilizing the positive and/or corrected form of the patient-adapted joint-facing surface.
4 . The method of claim 1 , further comprising inspecting the implant component utilizing a form of the joint-facing surface model and/or a form of the resected-bone surface model;
5 . The method of claim 1 , further comprising providing a positive form of the resected-bone surface model to a 3D printing apparatus; and printing a patient-adapted anatomical model that includes the positive form of the resected-bone surface.
6 . The method of claim 5 , further comprising placing the patient-adapted implant component onto the patient-adapted anatomical model; and inspecting the implant component.
7 . A method of making a surgical repair system for a patient, the method comprising:
receiving patient-specific data regarding the patient;
deriving a patient-adapted surface model from the patient-specific data;
providing a form of the patient-adapted surface model to at least one 3D printing apparatus;
printing a patient-adapted implant component that substantially includes the form of the patient-adapted surface model; and
removing one or more support structures from the implant component utilizing, at least in part, the first form of the patient-adapted surface model.
8 . The method of claim 7 , further comprising inspecting the implant component utilizing, at least in part, the first form of the patient-adapted surface model.
9 . The method of claim 7 , wherein the form of the patient-adapted surface model comprises a positive and/or corrected form of the patient-adapted surface model.
10 . The method of claim 7 , wherein the form of the patient-adapted surface model comprises a negative and/or uncorrected form of the patient-adapted surface model.
11 . A method of making a surgical repair system for a patient, the method comprising:
receiving patient-specific data regarding the patient;
deriving a patient-adapted surface model from the patient-specific data;
providing a positive and/or corrected form of the patient-adapted surface model to at least one 3D printing apparatus;
providing a negative and/or uncorrected form of the patient-adapted surface model to at least one 3D printing apparatus;
printing a patient-adapted implant component that substantially includes the positive and/or corrected form of the patient-adapted surface;
printing a patient-adapted instrument that substantially includes the negative and/or uncorrected form of the patient-adapted surface; and
printing a patient-adapted trial implant component that substantially includes the positive and/or corrected form of the patient-adapted surface.