Granted Patent B2

US 12,622,785 · App. 18/213,244 · Granted May 12, 2026

Inventors: Niall Patrick Casey (Carlsbad, CA); Michael J. Cordonnier (Carlsbad, CA)

Assignee: Carlsmed, Inc.

A61F2/30942A61B34/10A61F2/4455B33Y50/00B33Y80/00G05B19/4099A61F2002/30943A61F2002/30948A61F2002/30952A61F2002/3096A61F2002/30985G05B2219/35134G05B2219/49007

Abstract

Claims (165)

1 . A method comprising:

sending at least one image of a patient to a computer system programmed to perform an orthopedic implant design process for achieving a planned orthopedic correction, the orthopedic implant design process including:

generating a virtual model representing anatomy of the patient based on anatomy of interest in the at least one image;

manipulating one or more spatial relationships between anatomic elements of the virtual model to generate a corrected virtual model of the patient; and

after manipulating the one or more spatial relationships,

filling a negative space between the anatomic elements of the corrected virtual model with a virtual orthopedic implant; and

displaying, via a display, at least a portion of the corrected virtual model and one or more metrics associated with the portion of the corrected virtual model.

2 . The method of claim 1 , wherein the one or more metrics includes:

a first set of pre-corrective pathologic anatomy metrics for the patient, and

a second set of post-corrections corrected anatomy metrics for the patient.

3 . The method of claim 1 , further comprising displaying, via the display:

a pathology virtual model representing pre-correction pathology and associated pre-correction anatomic metrics; and

the corrected virtual model representing at least one planned anatomical correction and associated planned post-correction anatomic metrics.

4 . The method of claim 3 , further comprising displaying, via the display, a visual comparison of the pathology virtual model and the corrected virtual model.

5 . The method of claim 3 , wherein the pathology virtual model representing the anatomy of the patient based on segmented images of the anatomy of interest.

6 . The method of claim 1 , wherein the computer system is programmed to identify one or more implant locations along the virtual model for an anatomical correction, wherein the method further includes:

displaying the identified implant locations along the corrected virtual model representing the planned orthopedic correction.

7 . The method of claim 1 , further comprising generating one or more parameters of the virtual orthopedic implant based on relative positions of the anatomic elements of the corrected virtual model.

8 . The method of claim 1 , further comprising receiving user input for treating the patient, wherein manipulating the one or more spatial relationships between the anatomic elements is based on the received user input.

9 . The method of claim 1 , wherein manipulating the one or more spatial relationships includes positioning the anatomic elements at positions corresponding to a spinal correction.

10 . The method of claim 1 , further comprising:

sending user-inputted approval of the planned orthopedic correction prior to manufacturing the virtual orthopedic implant.

11 . The method of claim 1 , wherein the virtual orthopedic implant design process further includes:

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

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

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

12 . A system comprising:

one or more processors; and

a memory storing instructions that, when executed by the one or more processors, cause the system to perform a process comprising:

sending at least one image of a patient to a computer system programmed to perform an orthopedic implant design process for achieving a planned orthopedic correction, the orthopedic implant design process including:

generating a virtual model representing anatomy of the patient based on anatomy of interest in the at least one image;

manipulating one or more spatial relationships between anatomic elements of the virtual model to generate a corrected virtual model of the patient; and

after manipulating the one or more spatial relationships, filling a negative space between the anatomic elements of the corrected virtual model with a virtual orthopedic implant; and

displaying, via a display, at least a portion of the corrected virtual model and one or more metrics associated with the portion of the corrected virtual model.

13 . The system of claim 12 , wherein the one or more metrics includes:

a first set of pre-corrective pathologic anatomy metrics for the patient, and

a second set of post-corrections corrected anatomy metrics for the patient.

14 . The system of claim 12 , further comprising displaying, via the display:

a pathology virtual model representing pre-correction pathology and associated pre-correction anatomic metrics of the patient; and

the corrected virtual model representing at least one planned anatomical correction and associated planned post-correction anatomic metrics.

15 . The system of claim 12 , after manipulating the one or more spatial relationships, generating one or more parameters of the virtual orthopedic implant based on at least one relative position of the anatomic elements.

16 . A non-transitory computer-readable storage medium storing instructions that, when executed by a computing system, cause the computing system to perform operations comprising:

sending at least one image of a patient to a computer system programmed to perform an orthopedic implant design process for achieving a planned orthopedic correction, the orthopedic implant design process including:

generating a virtual model representing anatomy of the patient based on anatomy of interest in the at least one image;

manipulating one or more spatial relationships between anatomic elements of the virtual model to generate a corrected virtual model of the patient; and

after manipulating the one or more spatial relationships,

filling a negative space between the anatomic elements of the corrected virtual model with a virtual orthopedic implant; and

displaying, via a display, at least a portion of the corrected virtual model and one or more metrics associated with the portion of the corrected virtual model.

17 . The non-transitory computer-readable storage medium of claim 16 , wherein the one or more metrics includes:

a first set of pre-corrective pathologic anatomy metrics for the patient, and

a second set of post-corrections corrected anatomy metrics for the patient.

18 . The non-transitory computer-readable storage medium of claim 16 , wherein the operations further comprise displaying:

a pathology virtual model representing pre-correction pathology and associated pre-correction anatomic metrics of the patient; and

the corrected virtual model representing at least one planned anatomical correction and associated planned post-correction anatomic metrics.

19 . The non-transitory computer-readable storage medium of claim 16 , wherein the operations further include after manipulating the one or more spatial relationships, generating one or more parameters of the virtual orthopedic implant based on at least one relative position of the anatomic elements.

20 . The non-transitory computer-readable storage medium of claim 16 , further comprising:

sending user-inputted approval of a planned correction to manufacture the virtual orthopedic implant.

21 . A patient-specific orthopedic implant made by a process comprising:

sending at least one image of a patient to a computer system programmed to perform an orthopedic implant design process for achieving a planned orthopedic correction, the orthopedic implant design process including:

generating a virtual model representing anatomy of the patient based on anatomy of interest in the at least one image;

manipulating one or more spatial relationships between anatomic elements of the virtual model to generate a corrected virtual model of the patient; and

after manipulating the one or more spatial relationships,

filling a negative space between the anatomic elements of the corrected virtual model with a virtual patient-specific orthopedic implant; and

displaying, via a display, at least a portion of the corrected virtual model and one or more metrics associated with the portion of the corrected virtual model.

22 . A method comprising:

sending at least one image of a patient to a computer system programmed to perform an orthopedic implant design process for achieving a planned orthopedic correction, the orthopedic implant design process including:

generating a virtual model representing at least a portion of a spine of the patient based on anatomy of interest in the at least one image;

manipulating one or more spatial relationships between vertebrae of the virtual model to provide a corrected virtual model of the patient; and

after manipulating the one or more spatial relationships,

positioning a virtual orthopedic implant at a negative space between the vertebrae of the corrected virtual model; and

displaying, via a display, at least a portion of the corrected virtual model with the virtual orthopedic implant positioned at the negative space and one or more metrics associated with the portion of the corrected virtual model.

23 . The method of claim 22 , further comprising:

designing a spinal rod based on the planned orthopedic correction.

24 . A method comprising:

receiving, via a computer system, at least one image of a patient;

performing an orthopedic implant design process for achieving a planned orthopedic correction, the orthopedic implant design process including:

generating a virtual model representing at least a portion of a spine of the patient based on anatomy of interest in the at least one image;

manipulating one or more spatial relationships between vertebrae of the virtual model to provide a corrected virtual model of the patient; and

after manipulating the one or more spatial relationships,

positioning a virtual orthopedic implant at a negative space between the vertebrae of the corrected virtual model; and

sending a plan displayable via a display of a user device, to view at least a portion of the corrected virtual model with the virtual orthopedic implant positioned at the negative space and one or more metrics associated with the portion of the corrected virtual model.

25 . The method of claim 24 , wherein the patient is a first patient, the method further comprising:

segmenting the at least one image using a voxel-segmentation routine;

generating the virtual model representing the anatomy of interest based on the segmentation of the at least one image;

storing the virtual model in a database of an implant design computer system;

designing, using the implant design computer system, a patient-specific implant designed based on the virtual model;

after the patient-specific implant is implanted in the first patient,

receiving a set of post-operative images of the first patient,

training the implant design computer system using at least one of the set of post-operative images of the first patient, and

designing, via the implant design computer system, at least one patient-specific implant for a second patient using a virtual model of the second patient representing a second planned outcome for the second patient.

26 . The method of claim 24 , further comprising:

determining, using the corrected virtual model and the computer system, one or more relationships between vertebrae of the spine;

obtaining an implant design constraint from a database;

designing, using the computer system, a patient-specific implant based on the one or more relationships and the implant design constraint;

generating a digital surgical plan showing the patient-specific implant positioned along the spine of the patient; and

sending the digital surgical plan to a user for viewing using the display of the user device.

27 . The method of claim 24 , further comprising:

defining perimeters of the vertebrae;

selecting one or more bounding anatomical features of the spine; and

designing the virtual orthopedic implant to be positioned relative to the perimeters and with a configuration selected based on the one or more bounding anatomical features.

28 . A system comprising:

one or more processors; and

a memory storing instructions that, when executed by the one or more processors, cause the system to perform a process comprising:

receiving, via a computer system, at least one image of a patient;

performing an orthopedic implant design process for achieving a planned orthopedic correction, the orthopedic implant design process including:

generating a virtual model representing at least a portion of a spine of the patient based on anatomy of interest in the at least one image;

manipulating one or more spatial relationships between vertebrae of the virtual model to provide a corrected virtual model of the patient; and

after manipulating the one or more spatial relationships,

positioning a virtual orthopedic implant at a negative space between the vertebrae of the corrected virtual model; and

sending a plan displayable via a display of a user device, to view at least a portion of the corrected virtual model with the virtual orthopedic implant positioned at the negative space and one or more metrics associated with the portion of the corrected virtual model.

29 . The system of claim 28 , wherein the patient is a first patient, wherein the process further comprises:

segmenting the at least one image using a voxel-segmentation routine;

generating the virtual model representing the anatomy of interest based on the segmentation of the at least one image;

storing the virtual model in a database of an implant design computer system;

designing, using the implant design computer system, a patient-specific implant designed based on the virtual model;

after the patient-specific implant is implanted in the first patient,

receiving a set of post-operative images of the first patient,

training the implant design computer system using at least one of the set of post-operative images of the first patient, and

designing, via the implant design computer system, at least one patient-specific implant for a second patient using a virtual model of the second patient representing a second planned outcome for the second patient.

30 . The system of claim 28 , wherein the process further comprises:

determining, using the corrected virtual model and the computer system, one or more relationships between vertebrae of the spine;

obtaining an implant design constraint from a database;

designing, using the computer system, a patient-specific implant based on the one or more relationships and the implant design constraint;

generating a digital surgical plan showing the patient-specific implant positioned along the spine of the patient; and

sending the digital surgical plan to a user for viewing using the display of the user device.

31 . The system of claim 28 , wherein the process further comprises:

defining perimeters of the vertebrae;

selecting one or more bounding anatomical features of the spine; and

designing the virtual orthopedic implant to be positioned relative to the perimeters and with a configuration selected based on the one or more bounding anatomical features.

32 . A method comprising:

receiving, using a computer system, at least one image of a patient;

generating, using the computer system, a virtual model representing at least a portion of a spine of the patient in the at least one image;

determining one or more spatial relationships between anatomical elements of the virtual model to represent an anatomical correction;

designing an orthopedic implant to be positioned between an upper vertebra and a lower vertebra of the spine based on the virtual model such that the orthopedic implant has

an upper region configured to match geometry of the upper vertebra,

a lower region configured to match geometry of the lower vertebra, and

a height for spacing apart the upper vertebra and the lower vertebra to achieve the anatomical correction when the orthopedic implant is implanted between the upper vertebra and the lower vertebra; and

causing display of at least one of (a) a portion of the virtual model representing the anatomical correction and one or more metrics associated with the anatomical correction or (b) the orthopedic implant.

33 . The method of claim 32 , further comprising:

segmenting the at least one image using a voxel-segmentation routine;

generating the virtual model representing an anatomy of interest based on the segmentation of the at least one image;

storing the virtual model in a database;

designing, using the computer system, the orthopedic implant based on the virtual model from the database;

after the orthopedic implant is implanted in the patient,

receiving a set of post-operative images of the patient,

training the computer system using at least one of the set of post-operative images of the patient, and

designing, via the computer system, at least one patient-specific implant for a subsequent patient using a virtual model of the subsequent patient representing a second planned outcome for the subsequent patient.

34 . The method of claim 32 , further comprising:

determining, using the virtual model and the computer system, one or more relationships between vertebrae of the spine;

obtaining an implant design constraint from a database;

designing, using the computer system, the orthopedic implant based on the one or more relationships and the implant design constraint;

generating a digital surgical plan showing the orthopedic implant positioned along the spine of the patient; and

sending the digital surgical plan to a user for viewing using a display of a user device.

35 . The method of claim 32 , further comprising positioning a virtual representation of the orthopedic implant at a negative space between the upper vertebra and the lower vertebra of the virtual model to evaluate the anatomical correction.

36 . The method of claim 32 , further comprising:

defining perimeters of vertebrae of the spine;

selecting one or more bounding anatomical features of the spine; and

designing the orthopedic implant to be positioned relative to the perimeters and with a configuration selected based on the one or more bounding anatomical features.

37 . The method of claim 32 , wherein at least one of the upper region or the lower region is configured to match an irregular surface of an adjacent vertebral endplate.

38 . The method of claim 32 , further comprising

analyzing a region of interest of the virtual model; and

selecting a footprint of the orthopedic implant based on the analysis.

39 . The method of claim 32 , further comprising manufacturing the orthopedic implant with a graft chamber and a lattice structure.

40 . The method of claim 32 , further comprising determining an optimal size for the orthopedic implant based on the virtual model.

41 . The method of claim 32 , further comprising segmenting an anatomy of interest in the at least one image using at least one of a threshold filter or a combination of filters.

Assignments (1)

Continuity (4)

References Cited (400)