Robot specific implant designs with contingent manual instrumentation

Abstract

A system and method are described herein for creating planar bone cuts on a bone to receive a total knee arthroplasty (TKA) femoral implant. The system includes a robotic surgical device, a computing system, and one or more contingent manual instruments. A surgical plan is generated having instructions for the robotic surgical device to create six or more planar bone cuts on the bone. The robotic surgical device executes the instructions, and in the event the robotic procedure is aborted before completing the six or more planar cuts, the one or more contingent manual instruments are used to create any remaining planar bone cuts. The one or more contingent manual instruments may include a plurality of uniquely arranged guide slots to assist a user in creating one or more remaining planar bone cuts.

1 - 9 . (canceled) 
     
     
         10 . A surgical system, comprising:
 a robotic arm for moving an end-effector;   a computer comprising a processor configured to control the robotic arm to create six or more planar bone cuts with the end-effector, wherein the six or more planar bone cuts are complementary to six or more planar surfaces of an implant; and   one or more manual instruments, each alone or in combination, configured to create any remaining planar bone cuts in the event the control of the robotic arm is aborted prior to the completion of the six or more planar bone cuts.   
     
     
         11 . The system of  claim 10  wherein said one or more manual instruments comprise a cut block having a plurality of guide slots. 
     
     
         12 . The system of  claim 11  wherein the cut block has six or more guide slots. 
     
     
         13 . The system of  claim 10  wherein said one or more manual instruments comprises a set of cut blocks, wherein each cut block of the set of cut blocks has one or more guide slots at a unique angle and position compared to the other cut blocks of the set of cut blocks. 
     
     
         14 . The system of  claim 10  wherein the one or more manual instruments comprise a mating surface that negatively matches a surface of the bone. 
     
     
         15 . The system of  claim 10  wherein the one or more manual instruments comprise a three-dimensional (3-D) printed cut guide. 
     
     
         16 . The system of  claim 10  wherein the implant is custom designed with a planning software program. 
     
     
         17 . The system of  claim 16  wherein the implant is a femoral total knee arthroplasty (TKA) implant 
     
     
         18 . The system of  claim 10  further comprising the implant. 
     
     
         19 . The system of  claim 18  wherein the implant is a femoral total knee arthroplasty (TKA) implant. 
     
     
         20 . The system of  claim 18  wherein the implant is custom designed with a planning software program. 
     
     
         21 . The system of  claim 19  further comprising the planning software program. 
     
     
         22 . The system of  claim 10  wherein the processor is further configured to control the robotic arm to create one or more peg holes in the femur prior to creating any other planar bone cuts. 
     
     
         23 . The system of  claim 22  wherein the one or more manual instruments comprise pegs for placement in the peg holes. 
     
     
         24 . The system of  claim 10  wherein the processor is further configured to control the robotic arm to create a distal cut plane on the femur and one or more peg holes on the distal cut plane prior to creating any other planar bone cuts. 
     
     
         25 . The system of  claim 24  wherein the one or more manual instruments comprise pegs for placement in the peg holes. 
     
     
         26 . The system of  claim 10  wherein the processor is configured to automatically control the robotic arm. 
     
     
         27 . The system of  claim 10  wherein the processor is configured to control the robotic arm by haptically constraining the robotic arm.