Method And Apparatus For Manufacturing An Implant

Abstract

An orthopedic device includes a femoral implant having a non-custom internal bone engagement surface. The femoral implant includes at least nine parameters adjusted preoperatively to correspond to a specific patient. The parameters can include patient-specific lengths, such as, for example, medial and lateral condyle widths and notch height, and patient-specific medial and lateral angles.

What is claimed is: 
     
         1 . An orthopedic device comprising:
 a femoral implant having a non-custom internal bone engagement surface, the femoral implant further including at least nine parameters adjusted preoperatively to correspond to a specific patient.   
     
     
         2 . The orthopedic device of  claim 1 , wherein the parameters include three patient-specific lengths. 
     
     
         3 . The orthopedic device of  claim 2 , wherein the patient-specific lengths include a medial condyle width. 
     
     
         4 . The orthopedic device of  claim 2 , wherein the patient-specific lengths include a lateral condyle width. 
     
     
         5 . The orthopedic device of  claim 2 , wherein the patient-specific lengths include a notch height. 
     
     
         6 . The orthopedic device of  claim 1 , wherein the parameters include six patient-specific angles. 
     
     
         7 . The orthopedic device of  claim 1 , wherein the six patient-specific angles include three medial angles and three lateral angles. 
     
     
         8 . The orthopedic device of  claim 1 , further comprising a surgical kit including the femoral implant and a patient-specific alignment guide. 
     
     
         9 . The orthopedic device of  claim 9 , wherein the surgical kit includes reusable instruments. 
     
     
         10 . The orthopedic device of  claim 8 , wherein the surgical kit includes a drill guide and a cutting block. 
     
     
         11 . The orthopedic device of  claim 8 , wherein the surgical kit includes a tracking tag. 
     
     
         12 . The orthopedic device of  claim 8 , wherein the patient-specific alignment guide includes a removable tracking tag. 
     
     
         13 . An orthopedic device comprising:
 a femoral implant having a non-custom internal engagement surface, the femoral implant further including three patient-specific lengths, three patient specific medial angles and three patient-specific lateral angles, wherein the lengths and medial and lateral angles are selected preoperatively based on a three-dimensional image of an anatomy of a patient to match the anatomy of the patient.   
     
     
         14 . The orthopedic device of  claim 13 , wherein the patient specific lengths include a medial condyle width, a lateral condyle width and a notch height. 
     
     
         15 . The orthopedic device of  claim 13 , further comprising a surgical kit including the femoral implant and a patient-specific alignment guide including a removable tracking tag. 
     
     
         16 . The orthopedic device of  claim 13 , further comprising a disposable instrument kit including only disposable instruments. 
     
     
         17 . The orthopedic device of  claim 16 , wherein the instrument kit includes disposable patient-specific alignment guides.