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EP-3470002-B1 - SURGICAL GUIDES FROM SCANNED IMPLANT DATA

EP3470002B1EP 3470002 B1EP3470002 B1EP 3470002B1EP-3470002-B1

Inventors

  • DAVISON, ANDREW, CHARLES
  • MEST, John, Wayne

Dates

Publication Date
20260506
Application Date
20130311

Claims (5)

  1. A method of making a patient specific surgical guide that is configured to guide a movement of a cutting tool (101) toward a tissue body (10), the method comprising: scanning a physical model of a fixation member (322) having a post-operative shape so as to generate scanned image data; obtaining, from the scanned image data, a virtual three-dimensional model (516) of the fixation member (322) having a planned post-operative shape and defining at least one hole (326) that is configured to receive a fastener; processing the virtual three-dimensional model (516) of the fixation member (322) so as to couple the virtual three-dimensional model (516) of the fixation member (322) to a first virtual three-dimensional model (520) of the tissue body (10),wherein the first virtual three-dimensional model (520) of the tissue body (10) defines a first region (11), such that a central axis (X) of the at least one hole (326) is substantially aligned with a first target location (M) of the first region (11); creating a virtual three-dimensional model (522) of a guide (600) that defines at least one second virtual hole (606a, 606b); and processing the virtual three-dimensional model (522) of the guide (600) so as to couple the virtual three-dimensional model (522) of the guide (600) to a second virtual three-dimensional model (521) of the tissue body (10) having a second region (15) that is identical to the first region (11), such that a central axis (X) of the at least one second virtual hole (606a, b) of the virtual three-dimensional model (522) of the guide (600) is aligned with a second target location (N) of the second virtual three-dimensional model (521) of the tissue body (10), wherein the second target location (N) is positioned identically with respect to the first target location (M) relative to the respective first and second virtual three-dimensional models (520, 521) of the tissue body (10).
  2. The method of claim 1, wherein the physical model of the fixation member (322) has at least one hole (326).
  3. The method of claim 2, further comprising inserting a marker (502) into the at least one hole (326) of the physical model of the fixation member (322) to identify a path of the at least one hole relative to a thickness of the fixation member prior to the scanning step, wherein, the scanning step includes scanning the physical model of the fixation member (322) carrying the marker (502); the first obtaining step includes obtaining, from the scanned image data, a virtual three-dimensional model (518) of the marker (502); and the method further comprises processing the virtual three-dimensional model (516) of the fixation member (322) so as to generate the virtual hole (326) having a location and orientation corresponding to a location and orientation of the virtual three-dimensional model of the marker (502) in relation to the virtual three-dimensional model (516) of the fixation member (322), wherein the physical model of the fixation member (322) is coupled to a physical model (500) of the tissue body (10) having an intra- or post-operative shape during the scanning step, the method further comprising coupling the physical model of the fixation member (322) to the physical model of the tissue body (10) prior to scanning the physical model of the fixation member (322).
  4. The method of claim 3, further comprising obtaining the physical model (500) of the tissue body (10) prior to the scanning step, comprising: scanning the tissue body (10) so as to generate scanned image data of the tissue body (10); and obtaining, from the scanned image data of the tissue body (10), a third virtual three-dimensional model of the tissue body (10) having a pre-operative shape, wherein obtaining the physical model (500) of the tissue body (10) further comprises: manipulating the third virtual three-dimensional model of the tissue body (10) into an intra- or post-operative configuration so as to generate the first virtual three-dimensional model (520) of the tissue body (10); and constructing the physical model of the tissue body (10) identical to the first virtual three-dimensional model (520) of the tissue body (10).
  5. The method of claim 1, further comprising bending the physical model of the fixation member to the post-operative shape so as to conform an inner surface (325) of the physical model of the fixation member (322) to at least a portion of an outer surface (323) of the physical model of the tissue body (10).

Description

TECHNICAL FIELD The present disclosure generally relates to a method for manufacturing a surgical guide, and more particularly, to a method for manufacturing a patient specific resection guide. BACKGROUND Many surgical procedures require accurate cuts of bone. For example, in mandibular reconstruction surgery, deficient or infectious portions of the mandible may be removed from the patient and replaced with bone graft. In some instances, a surgeon performing mandibular reconstruction surgery typically makes several cuts on the mandible to properly fit a bone graft. To make an accurate cut, the surgeon may use a resection guide to guide the motion of the resection tool toward the bone. The resection guide can also be used to cut a bone portion from other anatomic locations of the patient in order to harvest bone grafts. US 2010/0152782 A1 discloses a surgical kit including a patient-specific alignment guide having a three-dimensional engagement surface custom-made by computer imaging to conform to a corresponding portion of a patient's tibial bone. The patient-specific alignment guide defines an elongated planar slot for guiding a blade and may define apertures for preparing holes in bone for fixation of a bone plate. The slot and apertures may be at a position selected during a pre-operative planning stage. US 2012/029574 A1 discloses an implant for use in orthognathic surgery of a mandible which may include a longitudinal plate member and a plurality of pre-configured guides coupled to the plate member. The longitudinal plate member is pre-bent to correspond to the post-operative shape of the mandible; and the guides are pre-configured to align the plate member with the mandible when the implant is positioned against the mandible after the mandible has been separated. As discussed above, resection guides are typically used to make accurate cuts on the patient's anatomy. Although many resection guides have been developed over the years, it is still desirable to produce resection guides that are specifically designed for a particular patient in order to enhance cutting accuracy. SUMMARY The present disclosure relates to methods of making a patient specific surgical guide that is configured to guide a movement of a tool toward a tissue body which is defined in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS The foregoing summary, as well as the following detailed description of the preferred embodiments of the application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the surgical instruments and methods of the present application, there is shown in the drawings preferred embodiments. It should be understood, however, that the application is not limited to the specific embodiments and methods disclosed, and reference is made to the claims for that purpose. In the drawings: Fig. 1A is a front elevation view of a resection guide coupled to a patient's tissue body;Fig. 1B is a side elevation view of the resection guide shown in Fig. 1A;Fig. 1C is a front elevation view of the tissue body shown in Fig. 1A after a tissue portion has been removed from the patient;Fig. 1D is a side elevation view of a virtual three-dimensional model of a graft source;Fig. 1E is a side elevation view of another resection guide coupled to the graft source;Fig. 1F is a perspective view of a fixation member coupled to the patient's tissue body shown in Fig. 1A;Fig. 2 is diagram illustrating the method of making any of the resection guides shown in Figs. 1A, 1B, and 1E;Fig. 3A illustrates a physical model of a tissue body in a pre-operative condition and a fixation member applied to the physical model;Fig. 3B illustrates a virtual three dimensional model of the physical model and fixation member shown Fig. 3B;Fig. 3C illustrates a virtual three-dimensional model of a resection guide fixation member applied to the tissue body in an intra- or post-operative configuration;Fig. 3D illustrates a virtual three dimensional model of a resection guide and a tissue body;Fig. 4A is a front elevation view of the fixation member shown in Fig. 1F;Fig. 4B is a top view of the a fixation member rand a marker shown in Fig. 4A;Figs. 5A and 5B illustrate a virtual three-dimensional model of the fixation member applied to the tissue body, and a virtual three-dimensional model of a resection guide applied to the graft source, respectively, illustrating how the virtual three-dimensional model of the resection guide includes elements that correspond to the virtual three-dimensional model of the fixation member;Fig. 6 is a flowchart that describes a method of making a resection guide in accordance with an embodiment of the present disclosure;Fig. 7 is a flowchart that describes a further method of making a resection guide; andFig. 8 is a flowchart that describes a further method of making a resection guide. DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS Certain terminology is used in the