Systems and methods for planning and performing image free implant revision surgery

1. A method of revising a total knee arthroplasty, the method comprising:

preparing, using a portion of a surgical instrument, a virtual three-dimensional model of an existing implant within a target bone, wherein the surgical instrument comprises a point probe, a first tracking array, and a cutting burr;

removing the existing implant from the target bone;

installing a second tracking array on a portion of the target bone;

preparing, using the point probe, a virtual three-dimensional model of the target bone following removal of the existing implant;

removing an unwanted portion of the target bone;

preparing, using the point probe, a virtual three-dimensional model of the target bone following removal of the unwanted portion;

generating a surgical plan using a surgical system, wherein the surgical plan comprises:

removing, using the cutting burr of the surgical instrument, a portion of the target bone according to a bone refinement plan, and

selecting and planning a fit of a revision implant and, optionally, at least one augment, and

wherein the surgical plan is based on at least one of the virtual three-dimensional model of the existing implant within the target bone, the virtual three-dimensional model of the target bone following removal of the existing implant, and the virtual three-dimensional model of the target bone following removal of the unwanted portion;

tracking a three-dimensional location and an orientation of each of the surgical instrument, the target bone, and the revision implant using a surgical navigation system; and

implanting the revision implant and, optionally, the at least one augment, according to the surgical plan.

2. The method of claim 1 , further comprising tracking alignment of:

(i) the target bone; and

(ii) at least one of: the virtual three-dimensional model of the existing implant within the target bone, the virtual three-dimensional model of the target bone following removal of the existing implant, and the virtual three-dimensional model of the target bone following removal of the unwanted portion using the surgical navigation system.

3. The method of claim 1 , wherein the at least one augment is selected from the group consisting of a femoral prosthetic augment, a tibial prosthetic augment, and a combination thereof.

4. The method of claim 1 , wherein the target bone is selected from the group consisting of a femur, a tibia, and a combination thereof.

5. The method of claim 1 , wherein the target bone comprises a femur and a tibia, and wherein the surgical plan further comprises balancing a gap between the femur and the tibia.

6. The method of claim 1 , wherein:

the target bone comprises a femur and a tibia;

the surgical plan further comprises determining a joint line reference; and

tracking the three-dimensional location and the orientation of the target bone includes tracking the joint line reference.

7. The method of claim 1 , further comprising collecting range-of-motion data and displaying the range-of-motion data virtually.

8. A system for revising a total knee arthroplasty, the system comprising:

a tracking system comprising a tracking sensor;

a surgical instrument comprising a cutting burr and a tracking array, wherein the tracking system is configured to monitor a current three-dimensional surgical instrument position and a current three-dimensional target bone position;

a control system comprising a communication interface and at least one processor coupled to a memory device, wherein the control system is coupled to the tracking system and is configured to receive tracking information identifying the current three-dimensional surgical instrument position and the current three-dimensional target bone position; and

a revision total knee implant and, optionally, at least one augment.

9. The system of claim 8 , wherein the memory device includes instructions that, when executed by the at least one processor, cause the control system to perform an operation selected from the group consisting of collecting at least one pre-defined parameter, generating a virtual three-dimensional model, collecting a plurality of surface points, generating a reshaped virtual three-dimensional model, generating a virtual revision plan for preparing a target bone for implantation of a revision implant, and combinations thereof.

10. The system of claim 9 , wherein the at least one pre-defined parameter characterizes an aspect of the target bone.

11. The system of claim 10 , wherein generating the three-dimensional model comprises using the at least one pre-defined parameter to model a shape of at least a portion of the target bone.

12. The system of claim 9 , wherein generating the reshaped three-dimensional model comprises:

collecting the plurality of surface points over a portion of the target bone surface associated with an implant revision procedure; and

generating the reshaped three-dimensional model based on the three-dimensional model and the plurality of surface points.

13. The system of claim 8 , wherein the memory device includes instructions that, when executed by the at least one processor, cause the control system to use at least one pre-defined parameter to align a three-dimensional model of a target bone within a working coordinate system.

14. The system of claim 8 , wherein the surgical instrument further comprises at least one of a burr guard, a plate probe attachment, and a point probe.

15. The system of claim 9 , wherein the target bone is selected from the group consisting of a femur, a tibia, and a combination thereof.

16. The system of claim 8 , wherein the at least one augment is selected from the group consisting of a femoral prosthetic augment, a tibial prosthetic augment, and a combination thereof.

17. The system of claim 8 , wherein the tracking system is an optical tracking system.