High accuracy molded navigation arrays, systems, and methods
Systems, methods, and devices are described for high accuracy molded navigation arrays. In a first embodiment, a navigation array is formed by molding, as a single component, an array having a plurality of marker regions. The marker regions include a reflective layer disposed thereon. In other embodiments, a navigation array is formed by molding over a frame having a plurality of marker elements. In still other embodiments, a navigation array is formed by molding over individual marker elements. In certain embodiments, a navigation array is formed by molding a frame with a plurality of voids and subsequently molding marker elements into each void where the marker elements include a reflective layer disposed thereon. In some embodiments, a navigation array is formed by molding a plurality of marker elements on a frame and disposing a reflective layer on the marker elements.
1. A navigation array for use in a computer-assisted surgical system, the array comprising:
a molded monolithic array body comprising:
a nonreflective frame region; and
a plurality of spaced apart marker regions;
wherein each of the marker regions has an associated reflective element configured to be detected and tracked by an optical tracking sensor.
2. The navigation array of claim 1 , wherein the frame region and the marker regions of the monolithic array body are comprised of the same material.
3. The navigation array of claim 2 , wherein the material is a polysulfone polymer or a polyether ether ketone polymer.
4. The navigation array of claim 1 , wherein the frame region of the monolithic array body is comprised of a first material, and the marker regions of the monolithic array body are comprised of a second material.
5. The navigation array of claim 4 , wherein the first material has a higher molding temperature than the second material.
6. The navigation array of claim 4 , wherein the first material is an acrylonitrile butadiene styrene polymer, an N,N-methylene-bis-acrylamide polymer, a polybutylene terephthalate polymer, a polymethyl methacrylate polymer, or an N,N-methylene-bis-acrylamide polymer.
7. The navigation array of claim 4 , wherein the second material is transparent.
8. The navigation array of claim 4 , wherein the second material is a polycarbonate polymer or a polyethyleneimine polymer.
9. The navigation array of claim 1 , wherein the marker regions of the monolithic array body are each coated with the reflective element.
10. The navigation array of claim 1 , wherein the reflective element is embedded in each of the marker regions of the monolithic array body.
11. The navigation array of claim 10 , wherein the marker regions can be detected and tracked by the optical tracking sensor from either side of the navigation array.
12. The navigation array of claim 1 , wherein the marker regions of the monolithic array body are all similarly shaped.
13. The navigation array of claim 1 , wherein at least two of the marker regions of the monolithic array body have different shapes.
14. The navigation array of claim 1 , wherein the marker regions of the monolithic array have unequal diameters between a first side of the array and a second side of the array.
15. The navigation array of claim 1 , further comprising an insert over molded into the monolithic array body.
16. A computer assisted surgical system, the system comprising:
a navigation array of claim 1 ;
an optical tracking unit associated with at least one optical tracking sensor; and
a control unit, wherein the control unit is adapted to utilize a predetermined fixed geometric relationship between the marker regions and detected positions of the marker regions to determine a three-dimensional position and orientation of the navigation array.
17. The system of claim 16 , further comprising a robot arm and a surgical instrument mounted to the robot arm.
18. The system of claim 17 , wherein the navigation array is adapted to be mounted to the robot arm or the surgical instrument.
19. A method manufacturing a navigation array of claim 1 , comprising:
injection molding, in a single operation, the monolithic array body.
20. A method manufacturing a navigation array of claim 1 , comprising:
over molding the monolithic array body over a navigation marker sub-assembly.