IP Library Granted Patent US 11,696,833
Granted Patent B2
US 11,696,833 · App. 16/569,494 · Granted Jul 11, 2023

Systems and methods for orthopedic implants

Inventors: Niall Patrick Casey (Carlsbad, CA); Michael J. Cordonnier (Carlsbad, CA)
Assignee: Carlsmed, Inc.
A61F2/30942A61B34/10A61F2/4455B33Y50/00B33Y80/00G05B19/4099A61F2002/3096A61F2002/30943A61F2002/30948A61F2002/30952A61F2002/30985G05B2219/35134G05B2219/49007
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Quick Facts
Patent No.
US 11,696,833
App. No.
16/569,494
Granted
Jul 11, 2023
Kind
B2
Abstract

A system and computer-implemented method for manufacturing an orthopedic implant involves segmenting features in an image of anatomy. Anatomic elements can be isolated. Spatial relationships between the isolated anatomic elements can be manipulated. Negative space between anatomic elements is mapped before and/or after manipulating the spatial relationships. At least a portion of the negative space can be filled with a virtual implant. The virtual implant can be used to design and manufacture a physical implant.

Claims (47)

1. A computer-implemented method for manufacturing an orthopedic implant, comprising:

segmenting anatomy of interest in at least one image of a subject;

isolating separate anatomic elements of the anatomy of interest;

manipulating spatial relationships between the isolated anatomic elements; and

after manipulating the spatial relationships,

mapping a negative space between the anatomic elements, and

filling at least a portion of the negative space with a virtual implant.

2. The method of claim 1 , further comprising after manipulating the spatial relationships,

generating one or more parameters of the virtual implant based on relative positions of the anatomic elements.

3. The method of claim 1 , wherein manipulating the spatial relationships includes positioning the isolated anatomic elements at positions corresponding to a corrective procedure.

4. The method of claim 1 , further comprising manufacturing the orthopedic implant according to one or more parameters of the virtual implant determined based on filling the at least the portion of the negative space with the virtual implant.

5. The method of claim 1 , wherein the at least one image includes a CT scan, an MRI scan, and/or an X-ray.

6. The method of claim 1 , further comprising imaging the anatomy of interest.

7. The method of claim 6 , wherein the imaging step is accomplished by using a CT machine, an MRI machine, and/or orthogonal bi-planar x-ray.

8. The method of claim 1 , wherein the segmenting step is accomplished by using a threshold filter and/or a combination of filters.

9. The method of claim 1 , wherein the isolating step is accomplished by using a volumetric grow operation.

10. The method of claim 1 , wherein the manipulating step is accomplished by translating the isolated body along an axis.

11. The method of claim 1 , wherein the manipulating step is accomplished by rotating the isolated element about an axis.

12. The method of claim 1 , wherein the manipulating step is accomplished by translating the isolated element about a curve.

13. The method of claim 1 , wherein the mapping step is accomplished by selecting a first bounding anatomical feature, selecting at least a second bounding anatomical feature and calculating the volume between the first and second bounding anatomical features.

14. The method of claim 1 further comprising defining an implant boundary.

15. The method of claim 4 , wherein the manufacturing step is accomplished by 3D printing, additive manufacturing, and/or subtractive manufacturing.

16. The method of claim 1 , further comprising manufacturing an implant with surfaces configured for timely release of therapeutic elements including antibiotics, anti-inflammatory, and/or bone proteins.

17. The method of claim 1 , further comprising:

creating a 3D model of the virtual implant based on the filling of the negative space with the virtual implant;

converting the 3D model into 3D fabrication data; and

manufacturing at least a portion of the orthopedic implant based on the 3D fabrication data.

18. The method of claim 1 , further comprising generating a virtual three-dimensional model of the anatomy of interest with the negative space.

19. The method of claim 18 , wherein filling the at least the portion of the negative space with the virtual implant is performed using the negative space of the virtual three-dimensional model.

20. The method of claim 1 , wherein the negative space is a three-dimensional negative space between the anatomic elements represented by virtual three-dimensional anatomic elements.

21. The method of claim 1 , wherein manipulating the spatial relationships between the isolated anatomic elements includes moving the anatomic elements to provide a corrective virtual model of the subject's spine with the negative space.

22. The method of claim 1 , further comprising generating a virtual three-dimensional corrective model of the subject's spine with the negative space.

23. The method of claim 22 , wherein filling the at least the portion of the negative space with the virtual implant is performed using the negative space of the virtual three-dimensional corrective model, wherein the virtual implant is a spine implant.

24. The method of claim 22 , wherein the negative space is a three-dimensional negative space between the anatomic elements represented by virtual three-dimensional anatomic elements.

25. A method for creating an orthopedic implant, the method comprising:

imaging anatomy;

segmenting anatomy of interest;

isolating separate anatomic elements;

manipulating spatial relationships between anatomic elements;

identifying a negative space between anatomic elements;

filling at least a portion of the negative space with a virtual implant; and

manufacturing an implant from one or more parameters of the virtual implant.

26. The method of claim 25 , wherein the identifying step is accomplished by selecting a first bounding anatomical feature, selecting at least a second bounding anatomical feature and calculating the volume between bounding anatomical features.

27. The method of claim 25 , further comprising generating a virtual three-dimensional corrective model of the anatomy of interest, wherein the virtual three-dimensional corrective model defines the negative space.

28. The method of claim 27 , wherein filling the at least the portion of the negative space with the virtual implant is performed using the negative space of the virtual three-dimensional corrective model.

29. The method of claim 25 , wherein the negative space is a three-dimensional negative space between the anatomic elements represented by virtual three-dimensional anatomic elements in a corrected configuration.

30. The method of claim 25 , wherein manipulating the spatial relationships between anatomic elements includes moving the anatomic elements to provide a corrective virtual model.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 14, 2020
From: CORDONNIER, MICHAEL J.
To: CARLSMED, INC.
Reel/Frame 053498/0610 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 15, 2020
From: CASEY, NIALL PATRICK
To: CARLSMED, INC.
Reel/Frame 052937/0209 →
Continuity (2)
Provisional Application 62730336 · Sep 12, 2018
Related Publication 20200078180A1 · Mar 12, 2020
Cited By (11)
US 12,251,313 US 12,274,509 US 12,274,622 US 12,376,907 US 12,446,966 US 12,514,645 US 12,599,485 US 12,622,785 US 12,636,084 US 12,690,922 US 12,708,517