External fixation clamp and systems for medical procedures

Abstract

The present invention relates to an external fixation system including at least one pair of connected clamp units forming at least one clamp. Each of the clamp units includes: a first component comprising a molded metal, the first component having a first exterior surface having a plurality of voids formed therein to define a plurality of interconnected ribs and a first periphery having at least one first pin groove formed therein; and a second component mated to the first component and including a second periphery having at least one second pin groove formed therein, the at least one first pin groove and at least one second pin groove together forming a fixation pin holder. A fixation pin is held in at least one of the fixation pin holders.

1 . A method of forming an orthopedic clamp component, comprising:
 filling a mold with a metallic powder comprising metal granules, the mold having a plurality of void projections that are shaped to form a plurality of voids in a metal orthopedic clamp component, each void having one or more ribs around each void and at least one opening projection that forms an opening through the orthopedic clamp component; and   fusing the metal granules in the mold to form the metal orthopedic clamp component, the metal orthopedic clamp component having a first exterior surface having the plurality of voids corresponding to the plurality of void projections formed on the mold to define the plurality of ribs and a first periphery surface on the metal orthopedic clamp component having at least one pin groove.   
     
     
         2 . The method of  claim 1 , wherein the fusing comprises heating the metal granules to a fusion temperature. 
     
     
         3 . The method of  claim 1 , wherein the metallic powder further comprises at least one binder. 
     
     
         4 . The method of  claim 3 , further comprising removing the at least one binder during or after the fusing step. 
     
     
         5 . The method of  claim 1 , further comprising cooling the fused metal granules. 
     
     
         6 . The method of  claim 1 , wherein the fused metal granules are cooled in the mold. 
     
     
         7 . The method of  claim 1 , wherein the mold is partially filled with the metal granules for heating at a fusion temperature and pressure. 
     
     
         8 . The method of  claim 1 , wherein the metallic powder comprises iron, nickel, or a combination thereof. 
     
     
         9 . The method of  claim 1 , wherein the metal granules have an average particle size of 20 microns or less. 
     
     
         10 . The method of  claim 1 , wherein fusing the metal granules comprises heating the metal granules. 
     
     
         11 . The method of  claim 10 , wherein the metal granules are heated at a temperature of at least 500° C. 
     
     
         12 . The method of  claim 1  wherein the metal clamp component comprises a stainless steel. 
     
     
         13 . The method of  claim 1  wherein the metal clamp component comprises aluminum. 
     
     
         14 . The method of  claim 1  wherein the metal clamp component comprises titanium. 
     
     
         15 . The method of  claim 1  wherein one or more exterior surfaces of the metal orthopedic clamp component have a draft angle to facilitate removal from the mold. 
     
     
         16 . The method of  claim 1  wherein the voids have surrounding walls forming a plurality of ribs that are interconnected, wherein the surrounding walls have a draft angle between 0.5 degrees to 1.5 degrees. 
     
     
         17 . The method of  claim 1  further comprising sintering the metal orthopedic clamp component wherein the metal orthopedic clamp component reduces in size by at least 10% of volume during sintering. 
     
     
         18 . The method of  claim 1  further comprising fabricating a further metal orthopedic clamp component in the same mold, the metal clamp component and the further metal orthopedic clamp component being coupled together to form a clamp device configured to hold a pin for insertion in a bone. 
     
     
         19 . The method of  claim 1  wherein the metal orthopedic clamp component has a connector opening such that a connector can extend through the connector opening to couple the metal orthopedic clamp component to a further clamp component to form a clamp device configured to apply a compressive force to hold a pin for insertion in a bone. 
     
     
         20 . The method of  claim 1  wherein each void has surrounding interior surfaces defining the interconnected ribs extending from a connector opening, the connector opening surrounded by a rib structure. 
     
     
         21 . An orthopaedic clamp, comprising:
 a first clamp component comprising a molded metal, the first clamp component having a first exterior surface having a plurality of voids formed therein, each void being surrounded by a plurality of interconnected ribs, a first opening extending through the first exterior surface to a first interior surface opposite the first exterior surface, and a first periphery having at least one first pin groove formed therein.   
     
     
         22 . The clamp of  claim 21 , wherein the plurality of interconnected ribs are interconnected to one another by a hub surrounding the first opening wherein the hub defines a circular shape. 
     
     
         23 . (canceled) 
     
     
         24 . The clamp of  claim 21 , further comprising a second clamp component to be mated with the first interior surface of the first clamp component wherein the second clamp component includes a second periphery having at least one second pin groove formed therein, the at least one first pin groove and at least one second pin groove together forming a fixation pin holder for holding and compressing a fixation pin between the first clamp component and second clamp component and wherein the second clamp component further comprises a second interior surface having at least one locking feature formed therein. 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . The clamp of  claim 24 , wherein the at least one locking feature comprises a plurality of teeth. 
     
     
         28 . The clamp of  claim 24 , wherein the first interior surface has a first mating feature and the second clamp component has a second exterior surface with a second mating feature mated to the first mating feature to form an interference fit. 
     
     
         29 . The clamp of  claim 21 , wherein the first periphery has at least one tab that at least partially defines the at least one pin groove. 
     
     
         30 . The clamp of  claim 21 , wherein the first clamp component consists of the molded metal.