Personalized fit and functional designed medical prostheses and surgical instruments and methods for making

Abstract

Methods, devices and systems for virtual, remote and real-time collaboration between surgeons and engineers using system learning and intelligent and timely disbursement of design and performance information to engineering teams embarking on the preliminary design event of a personalized orthopaedic implant or personalize surgical instrument utilizing a case-based reasoning expert system. Additive manufacturing technology and statistically controlled advanced manufacturing processes quickly produce personalized medical devices worldwide.

What is claimed is: 
     
         1 . A method for personalizing medical biocompatible devices, comprising the steps of:
 selecting a location for implanting a biocompatible device in a patient;   designing a 3D design model of the biocompatible device;   manufacturing the biocompatible device from the 3D design model; and   implanting the biocompatible device in the patient.   
     
     
         2 . The method of  claim 1 , wherein the biocompatible device is selected from one of an orthopedic prothesis and an orthopedic implant. 
     
     
         3 . The method of  claim 1 , wherein the biocompatible device is selected from one of a dental prosthesis and a dental implant. 
     
     
         4 . The method of  claim 1 , wherein the biocompatible device is selected from one of a soft tissue prosthesis, a soft tissue implant, a hard tissue prosthesis and a hard tissue implant. 
     
     
         5 . The method of  claim 1 , wherein the biocompatible device is selected from a group consisting of long bones, plates, intramedullary rods, pins, joint prosthesis, pelvic reconstruction prosthesis, cranial reconstruction prosthesis, maxillofacial reconstruction prosthesis, dental prosthesis, external fixation devices for aligning long bones and the spine, sliding joints, overlapping plates, external or implantable orthopedic intervention prosthesis, adjustable fixtures, internal Ilizarov devices for enabling the expansion or lengthening of long bones, implantable non-orthopedic prosthesis for cardiovascular, neurological, digestive or interventional implant devices for soft or hard tissue repair, cardiovascular stents, urological stents, interventional tools, interventional guides to assist accurate preparation of the tissue to enable the proper fit of the device, and instruments for laparoscopic, interventional, radiological, and minimally invasive procedures for cardiovascular, neurological, digestive applications in soft or hard tissues. 
     
     
         6 . The method of  claim 1 , further comprising the step of:
 resecting bone from the selected location of the biocompatible device prior to the step of implanting the biocompatible device.   
     
     
         7 . The method of  claim 1 , wherein the designing and the manufacturing steps includes the steps of:
 designing and manufacturing the biocompatible device with materials that do not have hypersensitivity reactions to allergens and do not have multiple chemical sensitivities for the patient.   
     
     
         8 . The method of  claim 1 , wherein the designing and the manufacturing steps includes the steps of:
 designing and manufacturing the biocompatible device based on at least one of: genetic profile, metabolism, drug-responsiveness and medically assessed damage at the location of the implantation of the biocompatible device.   
     
     
         9 . The method of  claim 1 , wherein the designing and the manufacturing steps includes the steps of:
 designing and manufacturing the biocompatible device: in a manner calculated to distribute mechanical stresses and strains at an interface between the biocompatible device and the location of the implantation of the biocompatible device, to reduce likelihood of fatigue damage to the biocompatible device and the location of the implantation of the biocompatible device, and to maximize lifecycle of the biocompatible device in the patient.   
     
     
         10 . The method of  claim 1 , wherein the designing and the manufacturing steps includes the steps of:
 calculating a calculation to distribute mechanical stresses and strains at an interface between the biocompatible device by a finite element analysis based on patient's age, lifestyle choices and functions, and frequencies and levels of physical activities.   
     
     
         11 . The method of  claim 1 , wherein the patient is selected from a human patient or a non-human animal patient. 
     
     
         12 . A method for personalizing medical biocompatible devices, comprising the steps of:
 selecting a location for implanting a biocompatible device in a patient;   designing the biocompatible device;   manufacturing the biocompatible device from the designed biocompatible device; and   implanting the biocompatible device in the patient.   
     
     
         13 . The method of  claim 12 , wherein the steps of designing and manufacturing the biocompatible device includes the steps of:
 designing and manufacturing the biocompatible device with materials that do not have hypersensitivity reactions to allergens and do not have multiple chemical sensitivities for the patient.   
     
     
         14 . The method of  claim 12 , wherein the designing and the manufacturing steps includes the steps of:
 designing and manufacturing the biocompatible device based on at least one of: genetic profile, metabolism, drug-responsiveness and medically assessed damage at the location of the implantation of the biocompatible device.   
     
     
         15 . The method of  claim 12 , wherein the designing and the manufacturing steps includes the steps of:
 designing and manufacturing the biocompatible device: in a manner calculated to distribute mechanical stresses and strains at an interface between the biocompatible device and the location of the implantation of the biocompatible device, to reduce likelihood of fatigue damage to the biocompatible device and the location of the implantation of the biocompatible device, and to maximize lifecycle of the biocompatible device in the patient.   
     
     
         16 . The method of  claim 12 , wherein the designing and the manufacturing steps includes the steps of:
 calculating a calculation to distribute mechanical stresses and strains at an interface between the biocompatible device by a finite element analysis based on patient's age, lifestyle choices and functions, and frequencies and levels of physical activities.   
     
     
         17 . The method of  claim 12 , wherein the steps of designing and manufacturing the biocompatible device includes the steps of:
 designing and manufacturing the biocompatible device with materials that do not have hypersensitivity reactions to allergens and do not have multiple chemical sensitivities for the patient; and   designing and manufacturing the biocompatible device based on at least one of genetic profile, metabolism, drug-responsiveness and medically assessed damage at the location of the implantation of the biocompatible device.   
     
     
         18 . The method of  claim 12 , wherein the designing and the manufacturing steps includes the steps of:
 designing and manufacturing the biocompatible device: in a manner calculated to distribute mechanical stresses and strains at an interface between the biocompatible device and the location of the implantation of the biocompatible device, to reduce likelihood of fatigue damage to the biocompatible device and the location of the implantation of the biocompatible device, and to maximize lifecycle of the biocompatible device in the patient.   
     
     
         19 . The method of  claim 18 , wherein the designing and the manufacturing steps includes the steps of:
 calculating a calculation to distribute mechanical stresses and strains at an interface between the biocompatible device by a finite element analysis based on patient's age, lifestyle choices and functions, and frequencies and levels of physical activities.   
     
     
         20 . The method of  claim 12 , wherein the designing and the manufacturing steps includes the steps of:
 designing and manufacturing the biocompatible device with materials that do not have hypersensitivity reactions to allergens and do not have multiple chemical sensitivities for the patient;   designing and manufacturing the biocompatible device based on at least one of: genetic profile, metabolism, drug-responsiveness and medically assessed damage at the location of the implantation of the biocompatible device;   designing and manufacturing the biocompatible device: in a manner calculated to distribute mechanical stresses and strains at an interface between the biocompatible device and the location of the implantation of the biocompatible device, to reduce likelihood of fatigue damage to the biocompatible device and the location of the implantation of the biocompatible device, and to maximize lifecycle of the biocompatible device in the patient; and   calculating a calculation to distribute mechanical stresses and strains at an interface between the biocompatible device by a finite element analysis based on patient's age, lifestyle choices and functions, and frequencies and levels of physical activities, with a calculation to distribute mechanical stresses and strains at an interface between the biocompatible device by a finite element analysis based on patient's age, lifestyle choices and functions, and frequencies and levels of physical activities.