Systems and methods for orthopedic implants
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.
1 . A method comprising:
receiving at least one image of a patient;
generating, using a 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 a patient-specific interbody cage configured to be implanted along the spine of the patient, the patient-specific interbody cage including
a first patient-specific endplate with a first topography configured to match a first surface of a first vertebral endplate of the patient, wherein the first vertebral endplate includes a graft-receiving aperture;
a second patient-specific endplate with a second topography configured to match a second surface of a second vertebral endplate of the patient, wherein the first topography is different from the second topography;
a graft chamber extending from the graft-receiving aperture and configured to hold graft material delivered through the graft-receiving aperture;
a sidewall extending between the first vertebral endplate and the second vertebral endplate, wherein the sidewall includes at least one lattice region, and
a solid region extending from the at least one lattice region to the first patient-specific endplate, wherein the solid region at least partially defines a patient-specific solid edge region extending about and surrounding the first patient-specific endplate; and
manufacturing the patient-specific interbody cage.
2 . The method of claim 1 , 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 patient-specific interbody cage based on the one or more relationships and the implant design constraint;
generating a digital surgical plan showing the patient-specific interbody cage 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.
3 . The method of claim 1 , wherein the at least one lattice region includes a plurality of lattice regions separated from one another by respective solid struts of the sidewall.
4 . The method of claim 1 , further comprising providing a plurality of stock interbody implants, wherein each of the plurality of stock interbody implants is different from the patient-specific interbody cage.
5 . The method of claim 1 , further comprising providing a steam sterilization case and a set of stock interbody components having different sizes, wherein the set of stock interbody components is contained in the steam sterilization case.
6 . The method of claim 1 , further comprising:
storing a digital virtual solid model of anatomy of the patient,
storing a digital virtual model of the patient-specific interbody cage, and
sending manufacturing data to an additive manufacturing system for manufacturing the patient-specific interbody cage.
7 . The method of claim 6 , further comprising generating the manufacturing data based on the digital virtual model of the patient-specific interbody cage.
8 . The method of claim 1 , further comprising selecting a set of screws of different lengths and configured to be inserted into the spine of the patient and to be used with the patient-specific interbody cage.
9 . The method of claim 1 , wherein the patient-specific solid edge region is integrally formed with the first patient-specific endplate.
10 . An anti-subsidence spinal implant system comprising:
a patient-specific interbody cage configured to be implanted along a spine of a patient, the patient-specific interbody cage including
a first patient-specific endplate with a first topography configured to match a first surface of a first vertebral endplate of the patient, wherein the first vertebral endplate includes a graft-receiving aperture;
a second patient-specific endplate with a second topography configured to match a second surface of a second vertebral endplate of the patient, wherein the first topography is different from the second topography;
a graft chamber extending from the graft-receiving aperture and configured to hold graft material delivered through the graft-receiving aperture;
a sidewall extending between the first vertebral endplate and the second vertebral endplate, wherein the sidewall includes at least one lattice region, and
a solid region extending from the at least one lattice region to the first patient-specific endplate, wherein the solid region at least partially defines a patient-specific solid edge region extending about and surrounding the first patient-specific endplate.
11 . The anti-subsidence spinal implant system of claim 10 , further comprising an instrument configured to couple to the patient-specific interbody cage to position the patient-specific interbody cage between the first vertebral endplate and the second vertebral endplate.
12 . The anti-subsidence spinal implant system of claim 10 , wherein the at least one lattice region includes a plurality of lattice regions separated from one another by respective solid struts of the sidewall.
13 . The anti-subsidence spinal implant system of claim 10 , further comprising a plurality of stock interbody implants, wherein each of the plurality of stock interbody implants is different from the patient-specific interbody cage.
14 . The anti-subsidence spinal implant system of claim 10 , further comprising a steam sterilization case and a set of stock interbody components having different sizes, wherein the set of stock interbody components is contained in the steam sterilization case.
15 . The anti-subsidence spinal implant system of claim 10 , further comprising:
a digital virtual solid model of anatomy of the patient,
a digital virtual model of the patient-specific interbody cage, and
an additive manufacturing system configured to receive manufacturing data for manufacturing the patient-specific interbody cage.
16 . The anti-subsidence spinal implant system of claim 15 , further comprising a computer system configured to store the digital virtual solid model, store the digital virtual model, and generate the manufacturing data based on the digital virtual model of the patient-specific interbody cage.
17 . The anti-subsidence spinal implant system of claim 10 , further comprising a set of screws of different lengths and configured to be inserted into the spine of the patient and to be used with the patient-specific interbody cage.
18 . The anti-subsidence spinal implant system of claim 10 , wherein the patient-specific solid edge region is integrally formed with the first patient-specific endplate.
19 . An anti-subsidence spinal implant system comprising:
a patient-specific interbody cage configured to be implanted along a spine of a patient, the patient-specific interbody cage including
a first patient-specific endplate with a first irregular contoured surface to mate with a first vertebral endplate of the patient;
a second patient-specific endplate with a second irregular contoured surface to mate with a second vertebral endplate of the patient, wherein the first irregular contoured surface is different from the second irregular contoured surface; and
a body extending between the first vertebral endplate and the second vertebral endplate and defining a graft holding chamber, wherein the body includes
a plurality of lattice regions having different sizes and being located directly between the first patient-specific endplate and the second patient-specific endplate and defining at least a portion of the graft holding chamber,
a patient-specific solid edge region extending about an entire periphery of the first patient-specific endplate, and
a plurality of struts coupled to the patient-specific solid edge region and extending along one or more of the plurality of lattice regions.
20 . The anti-subsidence spinal implant system of claim 19 , further comprising an instrument configured to couple to the patient-specific interbody cage to position the patient-specific interbody cage between the first vertebral endplate and the second vertebral endplate.
21 . The anti-subsidence spinal implant system of claim 19 , wherein the body includes a sidewall encompassing the graft holding chamber, wherein all of the plurality of lattice regions positioned along the sidewall are spaced apart from both the first patient-specific endplate and the second patient-specific endplate.
22 . The anti-subsidence spinal implant system of claim 21 , wherein the plurality of lattice regions includes a plurality of lattice regions separated from one another by respective solid struts of the sidewall.
23 . The anti-subsidence spinal implant system of claim 19 , further comprising a plurality of stock interbody implants, wherein each of the plurality of stock interbody implants is different from the patient-specific interbody cage.
24 . The anti-subsidence spinal implant system of claim 19 , further comprising a steam sterilization case and a set of stock interbody components having different sizes, wherein the set of stock interbody components is contained in the steam sterilization case.
25 . The anti-subsidence spinal implant system of claim 19 , further comprising:
a digital virtual model of anatomy of the patient,
a digital virtual model of the patient-specific interbody cage, and
an additive manufacturing system configured to receive manufacturing data for manufacturing the patient-specific interbody cage, wherein the manufacturing data is generated from the digital virtual model of the patient-specific interbody cage.
26 . The anti-subsidence spinal implant system of claim 25 , further comprising a computer system configured to store the digital virtual model, store the digital virtual model, and generate the manufacturing data based on the digital virtual model of the patient-specific interbody cage.
27 . The anti-subsidence spinal implant system of claim 19 , further comprising a set of screws of different lengths and configured to be inserted into the spine of the patient and to be used with the patient-specific interbody cage.
28 . The anti-subsidence spinal implant system of claim 19 , wherein the patient-specific solid edge region is integrally formed with the first patient-specific endplate.