US20210236295A1 - Calcaneal prosthesis and method of forming the same - Google Patents
Calcaneal prosthesis and method of forming the same Download PDFInfo
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- US20210236295A1 US20210236295A1 US17/302,103 US202117302103A US2021236295A1 US 20210236295 A1 US20210236295 A1 US 20210236295A1 US 202117302103 A US202117302103 A US 202117302103A US 2021236295 A1 US2021236295 A1 US 2021236295A1
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Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
- A61B17/56—Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor
- A61B17/58—Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like
- A61B17/68—Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
- A61B17/72—Intramedullary pins, nails or other devices
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/3094—Designing or manufacturing processes
- A61F2/30942—Designing or manufacturing processes for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/42—Joints for wrists or ankles; for hands, e.g. fingers; for feet, e.g. toes
- A61F2/4202—Joints for wrists or ankles; for hands, e.g. fingers; for feet, e.g. toes for ankles
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
- A61F2/30771—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth applied in original prostheses, e.g. holes or grooves
- A61F2002/30878—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth applied in original prostheses, e.g. holes or grooves with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/3094—Designing or manufacturing processes
- A61F2/30942—Designing or manufacturing processes for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
- A61F2002/30962—Designing or manufacturing processes for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques using stereolithography
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/42—Joints for wrists or ankles; for hands, e.g. fingers; for feet, e.g. toes
- A61F2/4202—Joints for wrists or ankles; for hands, e.g. fingers; for feet, e.g. toes for ankles
- A61F2002/4212—Tarsal bones
- A61F2002/4215—Lateral row of tarsal bones
- A61F2002/4217—Calcaneum or calcaneus or heel bone
Definitions
- This disclosure relates generally to medical devices and more specifically to a calcaneal prosthesis.
- Arthrodesis refers to surgical fixation of a joint, ultimately resulting in bone fusion.
- An arthrodesis procedure induces ankylosis performed to relieve pain or provide support in a diseased or injured joint.
- Tibiotalocalcaneal or tibiocalcaneal arthrodesis (“TC”) is a salvage procedure for the treatment of joint disease or pain and dysfunction due to arthritic ankle and subtalar joints, e.g., Charcot disease.
- the surgeon may wish to achieve anatomic alignment, pain relief, and a stable, plantigrade foot. Secure fixation while preserving the surrounding soft tissue can also contribute to a successful outcome.
- Intramedullary (IM) nails also referred to as “rods” have been used for tibiotalocalcaneal or tibiocalcaneal arthrodesis.
- the IM nail fixes the calcaneus, talus and tibia in alignment, for fusing these three bones together.
- the surgeon can lock the IM nail using bone screws connected to each end of the IM nail.
- the bone screws fix the position of the IM nail relative to the cortical bone.
- a calcaneal prosthesis system comprises a body having a dorsal surface, a plantar surface, an anterior surface, and a posterior end.
- the posterior end has a tuberosity.
- the anterior surface has at least a concavity or convexity or flat surface shaped for receiving a cuboid bone.
- the dorsal surface includes a convex, concave, or flat surface for engaging a talus bone.
- the body has a first previously formed surface defining a hole extending therethrough for receiving an intramedullary (IM) nail. The hole extends from the plantar surface of the body to the dorsal surface.
- IM intramedullary
- a calcaneal prosthesis comprises a single-piece body having a dorsal surface, an anterior surface, and a posterior end.
- the posterior end has a tuberosity.
- the anterior surface has a concavity shaped for receiving a cuboid bone or mid-foot bone(s).
- the dorsal surface includes a convex surface for engaging a talus bone or distal tibia.
- the unitary body has an integral intramedullary (IM) nail protruding from the dorsal surface.
- IM intramedullary
- a method of making a calcaneal prosthesis includes: collecting image data defining a first three-dimensional (3D) model of a first calcaneus of a patient; forming a second 3D model of a second calcaneus by computing a mirror image of the first 3D model about a sagittal plane; adding to the second 3D model at least one surface defining a hole that extends through the second calcaneus, the hole sized and shaped to receive an intramedullary nail; and fabricating the calcaneal prosthesis according to the second 3D model, using an additive manufacturing process.
- 3D three-dimensional
- FIG. 1 is a medial view of a left foot with a calcaneal prosthesis system.
- FIG. 2 is a medial isometric view of the calcaneal prosthesis system of FIG. 1 .
- FIG. 3 is a posterior view of the calcaneal prosthesis system of FIG. 1 .
- FIG. 4 is a lateral view of the calcaneal prosthesis system of FIG. 1 .
- FIG. 5 is an anterior view of the calcaneal prosthesis system of FIG. 1 .
- FIG. 6 is a superior view of the calcaneal prosthesis system of FIG. 1 .
- FIG. 7 is a medial view of a left foot with a variation of the calcaneal prosthesis system of FIG. 1 .
- FIG. 7A is an enlarged detail of FIG. 7 .
- FIG. 8 is a medial isometric view of a single-piece calcaneal prosthesis system.
- FIG. 9 is a posterior view of the calcaneal prosthesis system of FIG. 8 .
- FIG. 10 is a lateral view of the calcaneal prosthesis system of FIG. 8 .
- FIG. 11 is an anterior view of the calcaneal prosthesis system of FIG. 8 .
- FIG. 12 is a superior view of the calcaneal prosthesis system of FIG. 8 .
- FIG. 13 is a posterior view of a variation of the calcaneal prosthesis system shown in FIG. 3 .
- FIG. 14 is a superior view of a variation of the calcaneal prosthesis system of FIG. 1 .
- FIG. 15 is a superior view of a variation of the calcaneal prosthesis system of FIG. 14 .
- FIG. 16 is a superior view of a variation of the calcaneal prosthesis system of FIG. 1 .
- FIG. 17 is a flow chart of a method of making the prosthesis of FIG. 1 .
- This disclosure describes a calcaneal prosthesis having one or more pre-drilled holes configured for receiving at least an intramedullary (IM) nail.
- This disclosure also describes a single-piece calcaneal prosthesis having an integrally formed IM nail extending from a dorsal surface of the calcaneal prosthesis.
- the calcaneal prosthesis provides a strong base for retaining the IM nail in position for fusing the calcaneal prosthesis, talus and tibia.
- calcaneal prosthesis systems are provided.
- FIGS. 1-6 show a first embodiment of a calcaneal prosthesis 100 .
- FIG. 1 is a schematic diagram of a left foot having a calcaneal prosthesis 100 and intramedullary nail 150 implanted therein.
- the calcaneal prosthesis 100 is configured to approximate the shape and function of a natural calcaneus, including the calcaneal tuberosity 119 .
- the prosthesis 100 has a dorsal surface adapted to abut a resected talus 200 or resected tibia.
- the prosthesis 100 has an anterior surface adapted to abut a resected cuboid 202 and/or mid-foot bones. In the configuration shown in FIG.
- the IM nail 150 is inserted through the calcaneal prosthesis 100 , the talus 200 and the tibia 204 , for fusing the calcaneal prosthesis 100 , the talus 200 and the tibia 204 together.
- the prosthesis 100 can have an extended plantar-dorsal height, and the IM nail 150 is extended through the calcaneal prosthesis 100 , and directly into the tibia 204 .
- a calcaneal prosthesis system 180 may be employed including the calcaneal prosthesis 100 .
- the calcaneal prosthesis system 180 comprises a body 110 having a dorsal surface 112 , a plantar surface 114 , a medial surface 113 , a lateral surface 115 , an anterior surface 116 , and a posterior end 118 .
- the anterior (A), medial (M) and dorsal (D) directions are shown in FIG. 2 .
- the posterior end 118 has a tuberosity 119 .
- the tuberosity 119 extends in an oblique direction relative to an anterior-posterior (A) direction of the body.
- the anterior surface 116 has a concavity, convexity or flat surface shaped for receiving the cuboid bone 202 or mid-foot bone(s).
- the anterior surface 116 can include a concavity 116 c as shown in FIG. 2 .
- the concavity is shaped as an articulating surface for articulating motion with respect to the cuboid 202 —or mid-foot bone(s) in a case where the surgeon makes a biplanar wedge cut to the mid-foot.
- the anterior surface can include a trapezoid-shaped projection or a trapezoid-shaped recess, respectively, for abutting a resected cuboid (not shown) and/or mid-foot bone(s), not shown.
- the dorsal surface 112 includes a convex surface for engaging a talus bone 200 and/or tibia.
- the dorsal surface 112 can include a trapezoid-shaped convexity 130 as shown in FIG. 2 , adapted to be received by a recess in a resected talus (not shown).
- the exemplary trapezoid-shaped convexity 130 has the general form of a truncated pyramid, with trapezoidal surfaces on the medial, lateral, anterior and posterior sides, to facilitate an approach from any direction the surgeon may choose. In other embodiments described below with reference to FIG.
- the dorsal surface can include a trapezoid-shaped recess, for abutting a corresponding projection of a resected talus (not shown).
- a concave or flat surface can be substituted for the convex surface on the dorsal surface 112 of the body.
- convex surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a protuberance; concave surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a recess.
- the body 110 has a pre-formed surface defining a hole 104 therethrough for receiving an IM nail 150 .
- the previously formed hole 104 may be pre-drilled, or pre-made by forging, casting and/or machining.
- the surfaces defining the holes 104 are formed as part of an additive manufacturing (AM) process, such as 3D printing or direct metal laser sintering (DMLS) as discussed below. If an AM process is used, the prosthesis 100 is formed as a plurality of stacked monolayers, and holes are formed by voids at selected locations within the monolayers.
- the surfaces defining pre-formed hole 104 may be pre-planned using patient specific planning.
- the detailed shape of the non-degraded calcaneus is determined (e.g., by CT scan), a mirror image of the shape is formed about the mid-sagittal plane, and an AM process is used to construct the prosthesis according to the mirror image.
- a patient-specific manufacturing method for forming the prosthesis 100 is described below in the discussion of FIG. 17 .
- one or more “generic” calcaneus implants can be provided with multiple sizes. For example, after removing the degraded calcaneal tissue, the surgeon can insert one or more calcaneal prosthesis trials (not shown) for purpose of finding the standard size calcaneal prosthesis that most closely fits the foot anatomy of the patient. The surgeon then implants a calcaneal prosthesis having a size corresponding to the most closely-fitting calcaneal prosthesis trial. If the trial method is used, the surgeon can fit the calcaneal prosthesis without scanning the healthy calcaneus of the opposite foot.
- the hole 104 extends from the plantar surface 114 of the body 110 to the dorsal surface 112 of the body 110 .
- the surface defining hole 104 is formed at the same time the prosthesis is formed.
- the surface defining hole 104 may be formed at any time point before, during or after the machining process. Forming the surface defining hole 104 at the beginning of machining provides more options for stabilizing the piece of material from which the prosthesis is formed during the remainder of the machining. Forming the surface defining hole 104 during fabrication of the calcaneal prosthesis 100 reduces the length of the surgery preparation and avoids the difficulty of the surgeon drilling an aligned hole in the irregularly shaped calcaneal prosthesis 100 .
- a plurality of fastener openings penetrate the body 110 from the medial surface 113 , lateral surface 115 , anterior surface 116 and/or posterior end 118 .
- the fastener openings 105 , 106 extend from the external surface of the calcaneal prosthesis 100 to the hole 104 .
- the IM nail 150 has a set screw that can be advanced within the nail to compress the joint.
- the surgeon can implant bone screws into the calcaneal prosthesis 100 and into aligned screw-receiving holes in the IM nail, to stabilize the IM nail and prevent it from loosening or moving.
- Prosthesis 100 can also have surfaces defining additional fixation holes from medial, lateral, or posterior side of the calcaneal to fuse calcaneal to cuboid and/or mid-foot bones.
- FIGS. 2-6 show a fastener opening 106 on the medial surface 113 and a fastener opening 105 on the lateral surface 115 .
- the at least one fastener opening can be oriented at an oblique angle relative to the hole. These are just exemplary locations and orientations.
- the fastener opening can be provided at different locations (not shown).
- the fastener openings 105 , 106 can be oriented at a variety of different angles. Additional fastener openings can be included, and the number of fastener openings is not limited to two.
- some embodiments also have surfaces defining additional fixation holes from medial, lateral, or posterior side of the calcaneal to fuse calcaneal to cuboid and/or mid-foot bones.
- the body 110 can have one or more openings 120 for receiving k-wires for external fixation.
- the example in FIGS. 1-6 has two openings 120 , but other embodiments can have any number of openings for external fixation.
- the openings 120 can extend part way into the body 110 or extend from one (e.g., lateral) side to the opposite (e.g., medial) side as shown.
- the k-wires can be attached to an external fixation device, such as a circular fixator or the like (not shown).
- the calcaneal prosthesis system 180 further comprises an intramedullary (IM) nail 150 shaped to extend through the hole 104 .
- the IM nail 150 has at least one aperture 151 , 152 configured to receive at least one fastener (e.g., a bone screw, not shown) extending through the at least one fastener opening 105 , 106 of the body 110 .
- a fastener e.g., a bone screw, not shown
- the IM nail 150 comprises a material such as titanium, a titanium alloy (e.g., Ti 6Al-4V) or stainless steel, or cobalt chrome (CoCr).
- a material such as titanium, a titanium alloy (e.g., Ti 6Al-4V) or stainless steel, or cobalt chrome (CoCr).
- the IM nail 150 has an elongated shape.
- the IM nail has a first diameter D 1 along its entire length, as shown in FIG. 2 .
- the IM nail has a stop to prevent the IM nail from moving toward the tibia 204 when pressure is applied to the foot.
- the exemplary calcaneal prosthesis system 180 allows implantation of an IM nail, even in the case where the patient's calcaneus is deteriorated, such as in the case of Charcot disease.
- the surgeon can replace the calcaneus with the calcaneus prosthesis 100 and then insert the IM nail 150 .
- the calcaneus prosthesis 100 provides a strong, aligned implant for securing the IM nail 150 .
- the previously formed surface defining hole 104 and fastener openings 105 , 106 avoid any need for the surgeon to drill through the calcaneus prosthesis 100 and avoid alignment errors due to incorrect drilling by the surgeon.
- FIGS. 1-6 show a calcaneal prosthesis system 180 for a left foot
- a calcaneal prosthesis for the right foot can share the same design elements arranged as a mirror image of calcaneal prosthesis system 180 with respect to the mid-sagittal plane.
- a method for implanting the calcaneal prosthesis system 180 of FIGS. 1-6 comprises implanting a calcaneal prosthesis 100 through a medial incision, a lateral incision, an anterior incision, or a posterior incision in a foot.
- a method of implanting the calcaneal prosthesis system 180 can include making an incision for inserting the calcaneal prosthesis 100 from a desired side (e.g., an anterior approach).
- a desired side e.g., an anterior approach
- the surgeon may resect the talus 200 to include a recess or a protuberance.
- the surgeon may place pins in the talus 200 and/or cuboid 202 for aligning the calcaneal prosthesis 100 during implantation.
- the calcaneal prosthesis 100 is inserted into the wound site.
- the calcaneal prosthesis 100 has a pre-planned hole 104 therethrough.
- the hole 104 extends from a plantar surface 114 of the calcaneal prosthesis to a dorsal surface 112 of the calcaneal prosthesis 100 .
- the surgeon drills to extend the hole for the IM nail 150 through the talus 200 and tibia 204 from a plantar approach. Then the IM nail 150 is inserted through a plantar incision in the foot and through the hole 104 of the calcaneal prosthesis 100 , through the talus 200 and into the tibia 204 .
- the surgeon inserts one or more bone screws through a fastener opening 105 , 106 in a medial side 113 , lateral side 115 , anterior side 116 , or posterior side 118 of the calcaneal prosthesis 100 and into a corresponding aperture in the IM nail 150 .
- the fasteners e.g., bone screws
- the fasteners are inserted through the calcaneal prosthesis 100 and into the apertures 151 , 152 , 155 of the IM nail 150 to lock the IM nail 150 in place.
- the surgeon may insert three screws: a transverse calcaneal screw, a posterior calcaneal screw, and subtalar screw (if the patient's talus is intact).
- the surgeon also inserts one or more bone screws through the tibia 204 and into the IM nail 150 .
- the calcaneal prosthesis system 180 can be advantageous if the surgeon wants to use an anterior, posterior, lateral or medial approach for inserting the calcaneal prosthesis 100 .
- FIG. 7 shows an embodiment of a calcaneal prosthesis system 780 in which the IM nail 750 has a shoulder 751 , and the calcaneal prosthesis 700 has a corresponding stop 752 for limiting a depth of insertion of the IM nail 750 .
- FIG. 7A is an enlarged detail of FIG. 7 , showing the shoulder 751 of IM nail 750 abutting the stop 752 within the hole.
- the IM nail 750 has a first portion 753 (e.g., a dorsal portion) with a first diameter D 1 , and a second portion 754 (e.g., plantar portion) with a second diameter D 2 different from the first diameter D 1 .
- a first portion 753 e.g., a dorsal portion
- a second portion 754 e.g., plantar portion
- the surface defining the hole in the body 700 has a first part 704 sized to receive the first portion 753 of the IM nail 750 and a second part 705 sized to receive the second portion 754 of the IM nail 750 .
- the stop 752 is located at the interface between the first part 704 and the second part 705 .
- the shoulder 751 of the IM nail 750 abuts the stop 752 and prevents the IM nail 750 from traveling further into the tibia 204 .
- the stop 752 can be formed by a counter bore 705 in the plantar surface of the calcaneal prosthesis 700 . In some embodiments, as shown in FIG. 7 the stop 752 is located within the calcaneal prosthesis 700 .
- IM nail 750 has an increase in diameter from D 1 to D 2 where the first portion 753 meets the second portion 754 , this is not a requirement. In other embodiments (not shown), the IM nail has a gradual taper from the first diameter D 1 to the second diameter D 2 .
- the calcaneal prosthesis 700 can have a corresponding gradual taper from the first diameter D 1 to the second diameter D 2 .
- the tapered portion (not shown) of the surface defining the hole in the calcaneal prosthesis can act as the stop.
- the second portion 754 of the IM nail 750 extends from the plantar surface of the calcaneal prosthesis to the dorsal surface of the calcaneal prosthesis.
- the surface defining hole 705 has the larger diameter D 2 for the entire distance from the plantar surface of the calcaneal prosthesis 700 to the dorsal surface of the calcaneal prosthesis.
- the surface defining hole 706 in the talus 200 and tibia 204 has the smaller diameter D 1 , and the cortical bone of the talus 200 provides the stop 752 .
- the method for implanting the calcaneal prosthesis 700 is similar to the method described above for implanting the calcaneal prosthesis system 180 of FIG. 1
- the IM nail 750 has a first portion 753 with a first diameter D 1 , a second portion 754 with a second diameter D 2 larger than the first diameter D 1 , and a shoulder 751 at an interface between the first portion 753 and the second portion 754 .
- the surface defining hole in the calcaneal prosthesis 700 has a first part 704 sized to receive the first portion 753 of the IM nail 750 and a second part 705 sized to receive the second portion 754 of the IM nail 750 .
- the step of inserting the IM nail 750 into the hole 704 , 705 includes advancing the IM nail 750 until the shoulder 751 of the IM nail 750 abuts the stop 752 of the opening 705 .
- FIGS. 8-12 show an embodiment of a single-piece calcaneal prosthesis 800 for a left foot. Except where expressly indicated below, the shape of the prosthesis 800 can be the same as the shape of the prosthesis 100 of FIGS. 1-6 .
- FIG. 8 is a schematic diagram of a left foot having a monolithic calcaneal prosthesis 800 having an integral intramedullary nail 850 formed of a single piece of material.
- the calcaneal prosthesis 800 is configured to approximate the shape and function of a natural calcaneus, including the calcaneal tuberosity 819 .
- the prosthesis 800 has a dorsal surface adapted to abut a resected talus 200 or resected tibia 204 .
- the prosthesis 800 has an anterior surface adapted to abut a resected cuboid 202 and/or mid-foot bones. In the configuration shown in FIG.
- the IM nail 850 is configured to be inserted through the talus 200 and the tibia 204 , for fusing the calcaneal prosthesis 800 , the talus 200 and the tibia 204 together.
- the prosthesis 800 can have an extended plantar-dorsal height, and the IM nail 850 is configured to extend directly into the tibia 204 .
- the calcaneal prosthesis system 880 comprises a body 810 having a dorsal surface 812 , a plantar surface 814 , a medial surface 813 , a lateral surface 815 , an anterior surface 816 , and a posterior end 818 .
- the anterior (A), medial (M) and dorsal (D) directions are shown in FIG. 8 .
- the posterior end 818 has a tuberosity 819 .
- the tuberosity 819 extends in an oblique direction relative to an anterior-posterior (A) direction of the body.
- the anterior surface 816 has a concavity, convexity or flat surface shaped for receiving the cuboid bone 202 or mid-foot bone(s).
- the anterior surface 816 can include a concavity 816 c as shown in FIG. 8 .
- the concavity is shaped as an articulating surface for articulating motion with respect to the cuboid 202 (or mid-foot bone(s) in a case where the surgeon makes a biplanar wedge cut to the mid-foot).
- FIGS. 8 the anterior surface 816 has a concavity, convexity or flat surface shaped for receiving the cuboid bone 202 or mid-foot bone(s).
- the anterior surface 816 can include a concavity 816 c as shown in FIG. 8 .
- the concavity is shaped as an articulating surface for articulating motion with respect to the cuboid 202 (or mid-foot bone(s) in a case where the surgeon makes
- the anterior surface can include a trapezoid-shaped projection or a trapezoid-shaped recess, respectively, for abutting a resected cuboid (not shown) and/or mid-foot bone(s), not shown.
- the dorsal surface 812 includes a convex surface for engaging a talus bone 200 and/or tibia.
- the dorsal surface 812 can include a trapezoid-shaped convexity 830 as shown in FIG. 8 , adapted to be received by a recess in a resected talus (not shown).
- the exemplary trapezoid-shaped convexity 830 has the general form of a truncated pyramid, with trapezoidal surfaces on the medial, lateral, anterior and posterior sides, to facilitate an approach from any direction the surgeon may choose.
- the dorsal surface can include a trapezoid-shaped recess, for abutting a corresponding projection of a resected talus (not shown).
- a concave or flat surface can be substituted for the convex surface on the dorsal surface 812 of the body.
- convex surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a protuberance; concave surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a recess.
- the body 810 and IM nail 850 may be pre-drilled, or pre-made by forging, casting and/or machining.
- the body 810 and IM nail 850 are formed as part of an additive manufacturing (AM) process, such as 3D printing or direct metal laser sintering (DMLS) as discussed below.
- AM additive manufacturing
- DMLS direct metal laser sintering
- the prosthesis 800 is formed as a plurality of stacked monolayers, and the k-wire holes 820 are formed by voids at selected locations within the monolayers.
- the pre-formed holes 820 may be pre-planned using patient specific planning.
- the calcaneus prosthesis 800 can be a patient-specific prosthesis designed as a mirror image of a non-degraded calcaneus of the patient's opposite foot.
- the location and angulation of the implant holes and IM nail hole can be designed using a three-dimensional model to ensure that the fasteners and IM nail do not extend into one or more predetermined sections of a corresponding three-dimensional model of the patient's tissue, as determined by X-ray imagery.
- the IM nail 850 is formed at the same time the body 810 is formed.
- the IM nail 850 may be formed at any time point before, during or after machining the body 810 . Forming the surface defining hole 804 at the beginning of machining provides more options for stabilizing the piece of material from which the prosthesis is formed during the remainder of the machining. Forming the IM nail 850 during fabrication of the calcaneal prosthesis 800 reduces the length of the surgery preparation and avoids the difficulty of the surgeon drilling an aligned hole in the irregularly shaped calcaneal prosthesis 800 .
- the IM nail 850 has a set screw that can be advanced within the nail to compress the joint.
- Prosthesis 800 can also have additional surfaces defining fixation holes from medial, lateral, or posterior side of the calcaneal prosthesis 800 to fuse calcaneal prosthesis 800 to cuboid and/or mid-foot bones.
- the fastener opening can be provided at different locations (not shown).
- the fastener openings can be oriented at a variety of different angles. Additional fastener openings can be included, and the number of fastener openings is not limited to two.
- some embodiments also have additional surfaces defining fixation holes from medial, lateral, or posterior side of the calcaneal to fuse calcaneal to cuboid and/or mid-foot bones.
- the body 810 can have one or more openings 820 for receiving k-wires for external fixation.
- the example in FIGS. 8-12 has two openings 820 , but other embodiments can have any number of openings for external fixation.
- the openings 820 can extend part way into the body 810 or extend from one (e.g., lateral) side to the opposite (e.g., medial) side as shown.
- the k-wires can be attached to an external fixation device, such as a circular fixator or the like (not shown).
- the IM nail 850 has at least one aperture 851 , 852 configured to receive at least one fastener (e.g., a bone screw, not shown).
- at least one fastener e.g., a bone screw, not shown.
- the IM nail 850 has an elongated shape.
- the IM nail has a first diameter D 1 along its entire length, as shown in FIG. 8 .
- the IM nail has a stop to prevent the IM nail from moving toward the tibia 204 when pressure is applied to the foot.
- FIGS. 8-12 show a calcaneal prosthesis system 880 for a left foot
- a calcaneal prosthesis for the right foot can share the same design elements arranged as a mirror image of calcaneal prosthesis system 880 with respect to the mid-sagittal plane.
- the single-piece calcaneal prosthesis 800 comprises a unitary (i.e., single-piece, monolithic) body 810 having a dorsal surface 812 , a plantar surface 814 , an anterior surface 816 , and a posterior end 818 .
- the posterior end 818 has a tuberosity 819 .
- the anterior surface 816 can have a concavity 816 c shaped for receiving a cuboid bone 202 or mid-foot bone(s). In other embodiments, a convex or flat surface can be substituted for the concavity 816 c .
- the dorsal surface 812 can include a convex surface 830 for engaging a talus bone 200 and/or distal tibia.
- a concave or flat surface can be substituted for the convexity 830 .
- the unitary body has an integral IM nail 850 protruding from the dorsal surface 812 .
- the integral IM nail protrudes from the convex surface 830 of the dorsal surface 812 .
- a concave or flat surface can be substituted for the convex surface 830 .
- the integral IM nail 850 has at least one aperture 851 , 852 at an end of the IM nail opposite from the body 810 .
- the surgeon can insert fasteners (e.g., bone screws) through the cortical bone of the tibia 204 and/or talus 200 and into the apertures 851 , 852 to fix and stabilize the IM nail 850 .
- the apertures 851 , 852 are configured to receive fasteners oriented at an oblique angle relative to a longitudinal axis 840 of the IM nail 850 .
- the body can have one or more openings 820 for receiving k-wires for external fixation.
- the single-piece prosthesis 800 can eliminate separate installation steps for the IM nail 850 , and eliminate fasteners (e.g., bone screws) for fixing the IM nail 850 to the calcaneal prosthesis.
- the hole 104 is omitted from the calcaneal prosthesis 800 , because the IM nail 850 is not a separate piece and is not inserted into a hole in the calcaneal prosthesis 800 .
- the fastener openings 105 , 106 in the side surfaces of the calcaneal prosthesis 100 can also be omitted, because fasteners are not used to lock the IM nail to the calcaneal prosthesis.
- the single-piece construction of prosthesis 800 eliminates the separate steps of inserting the calcaneal prosthesis 100 and then inserting the IM nail 150 , as described above with reference to FIGS. 1-7 .
- the single-piece prosthesis is implanted from a plantar approach, and thus involves a larger plantar incision than the calcaneal prosthesis system 180 .
- the surgeon makes an incision in the plantar surface of the foot. Any remaining calcaneal bone is removed.
- the surgeon drills a plantar-dorsal hole through the talus 200 and into the longitudinal axis of the tibia 204 .
- the talus 200 is resected (via lateral or medial approach) to receive the dorsal convexity (or fit into a dorsal concavity) of the calcaneal prosthesis.
- the prosthesis 800 is inserted nail-first into the wound via plantar approach, and the IM nail 850 is inserted through the talus 200 and into the tibia 204 .
- FIG. 13 shows a calcaneal prosthesis system 1300 including a calcaneal prosthesis 1310 that is a variation of the calcaneal prosthesis 100 .
- Calcaneal prosthesis 1310 has a dorsal surface 1312 , a plantar surface 1314 , an anterior surface (not shown), a medial surface 1313 , a lateral surface 1315 , and a posterior end 1318 .
- the posterior end 1318 has a tuberosity 1319 .
- the anterior surface can have a concavity shaped for receiving the cuboid bone 202 and/or mid-foot bone(s).
- the calcaneal prosthesis 1310 can be the same as the calcaneal prosthesis 100 except that the anterior surface 1316 of the calcaneal prosthesis 1310 has a concave recess 1330 (e.g., a trapezoid-shaped recess) instead of the convexity 130 of calcaneal prosthesis 100 .
- the concave recess 1330 of the calcaneal prosthesis 1310 is configured to receive a resected talus having a trapezoid shaped protuberance.
- the calcaneal prosthesis 1300 can have the same configuration as the calcaneal prosthesis 100 .
- descriptions of the common features of calcaneal prosthesis 1310 and calcaneal prosthesis 100 are not repeated.
- FIG. 14 shows a calcaneal prosthesis system 1400 including a calcaneal prosthesis 1410 that is a variation of the calcaneal prosthesis 100 .
- Calcaneal prosthesis 1410 has a dorsal surface 1412 , a plantar surface (not shown), a medial surface 1413 , a lateral surface 1415 , and a posterior end 1418 .
- the posterior end 1418 has a tuberosity (not shown).
- the calcaneal prosthesis 1410 differs from the calcaneal prosthesis 100 in that the anterior surface 1416 of calcaneal prosthesis 1410 can have a convex protuberance for interfacing to a resected cuboid bone 202 having a trapezoidal recess.
- the anterior surface 1416 of calcaneal prosthesis 1410 can have a trapezoidal shape.
- the convex protuberance can provide added stability in the event the surgeon is going to fuse the cuboid 202 to the calcaneal prosthesis 1410 .
- the calcaneal prosthesis 1410 can have the same configuration as the calcaneal prosthesis 100 . For brevity, descriptions of the common features of calcaneal prosthesis 1410 and calcaneal prosthesis 100 are not repeated.
- FIG. 15 shows a calcaneal prosthesis system 1500 including a calcaneal prosthesis 1510 that is a variation of the calcaneal prosthesis 100 .
- Calcaneal prosthesis 1510 has a dorsal surface 1512 , a plantar surface (not shown), a medial surface 1513 , a lateral surface 1515 , and a posterior end 1518 .
- the posterior end 1518 has a tuberosity (not shown).
- the calcaneal prosthesis 1510 differs from the calcaneal prosthesis 100 in that the anterior surface 1516 of calcaneal prosthesis 1510 can have a concave recess for interfacing to a resected cuboid bone 202 having a trapezoidal protuberance.
- the anterior surface 1516 of calcaneal prosthesis 1510 can have a trapezoidal shape.
- the concave recess can provide added stability in the event the surgeon is going to fuse the cuboid 202 to the calcaneal prosthesis 1510 .
- the calcaneal prosthesis 1510 has surfaces defining additional holes (not shown) configured to receive fixation screws from through the calcaneal prosthesis and into the cuboid or mid-foot bones.
- the calcaneal prosthesis 1510 can have the same configuration as the calcaneal prosthesis 100 . For brevity, descriptions of the common features of calcaneal prosthesis 1510 and calcaneal prosthesis 100 are not repeated.
- FIG. 16 shows a calcaneal prosthesis system 1600 including a calcaneal prosthesis 1610 that is a variation of the calcaneal prosthesis 100 .
- Calcaneal prosthesis 1610 has a dorsal surface 1612 , a plantar surface (not shown), a medial surface 1613 , a lateral surface 1615 , an anterior surface 1616 , and a posterior end 1618 .
- the external shape of calcaneal prosthesis 1610 can be the same as the external surface of calcaneal prosthesis 100 . For brevity, a description of the external shape of the common features is not repeated.
- the posterior end 1618 has a tuberosity (not shown).
- the calcaneal prosthesis 1610 differs from the calcaneal prosthesis 100 in that the internal structure of calcaneal prosthesis 1610 has a lower average density than calcaneal prosthesis 100 .
- Calcaneal prosthesis 1610 can be substantially hollow to reduce weight, and can optionally include struts 1645 , 1646 for strength and a tube 1655 extending from the plantar surface (not shown) to the convex portion 1630 of dorsal surface 1612 .
- the struts 1645 and 1646 can be interconnected for additional strength.
- the tube 1655 is configured to receive the IM nail 150 .
- the calcaneal prosthesis 1610 can have the same configuration as the calcaneal prosthesis 100 .
- the calcaneal prosthesis 1610 comprises a porous material throughout the prosthesis.
- the interior of the calcaneal prosthesis 1610 has a porous material with a first density and one or more struts 1645 , 1646 formed of a continuous solid material having a second density greater than the first density.
- the remainder of the volume of the calcaneal prosthesis 1610 comprises the porous material.
- the porous material can have the same composition and a lower density than the struts 1645 , 1646 .
- a DMLS method can be used to form the calcaneal prosthesis with a variable density.
- the body 110 comprises a biocompatible material from the group consisting of metals such as titanium, stainless steel, absorbable magnesium, metal alloys; polymers such as polyethylene, ultra-high molecular weight polyethylene (UHMWPE), polyether ether ketone (PEEK), Polyetherketone (PEK), absorbable and non-absorbable polymers and copolymers; ceramics such as pyrocarbon; and combinations thereof. stainless steel.
- the body 110 may be coated with materials what may enhance biocompatibility such as, for example, plasma spray, hyaluronic acid, anti-microbial natural and synthetic polymers (e.g., vitamin E).
- the calcaneal prosthesis 100 can be formed by forging, casting, machining or direct metal laser sintering (DMLS).
- DMLS is an additive manufacturing (AM) process by which products can be printed using a laser or e-beam joining sequential layers of powder metal (e.g., Ti6Al4V or CoCr or Stainless Steel, for example) under automated computer control.
- AM additive manufacturing
- the calcaneal prosthesis 100 can be formed as a highly porous structure. Highly porous structures also provide good bone in-growth properties.
- the calcaneal prosthesis 100 can be formed as a continuous solid, having a rough surface or a highly porous layer at the surface.
- the calcaneal prosthesis 100 can have a porous surface layer with a thickness in a range from 0.01 inch to 0.1 inch.
- the porous surface layer has a thickness in a range from 0.03 inch to 0.07 inch.
- the porous surface layer has a thickness in a range from 0.04 inch to 0.06 inch.
- a first portion of the surface area of the calcaneal prosthesis 100 is porous, and a second portion of the surface area of the calcaneal prosthesis 100 is non-porous. For example, in the embodiment of FIGS.
- the calcaneal prosthesis 100 can have rough surface or porous layer at the dorsal surface 112 of the body 110 , and/or at the anterior surface 116 of the body 110 , with a smooth surface on the remaining sides.
- FIG. 17 is a flow chart of a method of making a calcaneal prosthesis as shown in FIGS. 1-16 . This method assumes that the patient's feet are symmetrical or nearly-symmetrical about the mid-sagittal plane, except for the deteriorated calcaneus in one foot.
- a set of image data are collected to define a first three-dimensional (3D) model of a first calcaneus (the healthy or non-degraded calcaneus) of a patient.
- the images can be collected by a tomography method, such as X-ray computed tomography (CT) or magnetic resonance imaging (MRI).
- CT computed tomography
- MRI magnetic resonance imaging
- a series of two-dimensional (2D) images (slices) of the patient's healthy calcaneus are collected.
- the images also include the talus and tibia.
- the 3D model is constructed from the 2D images, using a Radon transform, for example.
- a second 3D model of a second calcaneus is formed by computing a mirror image of the first 3D model about a sagittal plane.
- At step 1706 at least one surface defining a hole is added to the second 3D model.
- the hole extends through the second calcaneus, and is sized and shaped to receive an intramedullary nail.
- the hole is positioned so as to lie along the longitudinal axis of the tibia.
- fastener holes and/or guide wire holes are added to the 3D model.
- the location and angulation of the fastener holes and/or guide wire holes are adjusted such that the fasteners, guide wire holes and IM nail do not interfere with each other and do not contact specific tissue portions such as nerves.
- the location and angulation of the fastener holes, guide wire holes and IM nail hole can be designed using a three-dimensional model to ensure that the fasteners, guide wires (e.g., k-wires) and IM nail do not extend into one or more predetermined sections of a corresponding three-dimensional model of the patient's tissue, as determined by tomography.
- the calcaneal prosthesis is fabricated according to the second 3D model, using an additive manufacturing process.
- the calcaneus prosthesis 100 can be a patient-specific prosthesis designed as a mirror image of a non-degraded calcaneus of the patient's opposite foot.
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Abstract
A calcaneal prosthesis system includes a body having a dorsal surface, a plantar surface, an anterior surface, and a posterior end. The posterior end has a tuberosity. The anterior surface has at least a concavity or convexity shaped for receiving a cuboid bone or mid-foot bone. The dorsal surface includes a convex or concave surface for engaging a talus bone or distal tibia. An integrally formed intramedullary (IM) nail extends from the dorsal surface.
Description
- This application is a division of U.S. patent application Ser. No. 16/495,925, filed Sep. 20, 2019, which is a National Stage Application filed under 35 U.S.C. § 371 of International Patent Application No. PCT/US2017/037209, filed Jun. 13, 2017, the entireties of which are incorporated by reference herein.
- This disclosure relates generally to medical devices and more specifically to a calcaneal prosthesis.
- Arthrodesis refers to surgical fixation of a joint, ultimately resulting in bone fusion. An arthrodesis procedure induces ankylosis performed to relieve pain or provide support in a diseased or injured joint. Tibiotalocalcaneal or tibiocalcaneal arthrodesis (“TC”) is a salvage procedure for the treatment of joint disease or pain and dysfunction due to arthritic ankle and subtalar joints, e.g., Charcot disease. In performing ankle and subtalar arthrodesis, the surgeon may wish to achieve anatomic alignment, pain relief, and a stable, plantigrade foot. Secure fixation while preserving the surrounding soft tissue can also contribute to a successful outcome.
- Intramedullary (IM) nails (also referred to as “rods”) have been used for tibiotalocalcaneal or tibiocalcaneal arthrodesis. The IM nail fixes the calcaneus, talus and tibia in alignment, for fusing these three bones together. The surgeon can lock the IM nail using bone screws connected to each end of the IM nail. The bone screws fix the position of the IM nail relative to the cortical bone.
- In some embodiments, a calcaneal prosthesis system comprises a body having a dorsal surface, a plantar surface, an anterior surface, and a posterior end. The posterior end has a tuberosity. The anterior surface has at least a concavity or convexity or flat surface shaped for receiving a cuboid bone. The dorsal surface includes a convex, concave, or flat surface for engaging a talus bone. The body has a first previously formed surface defining a hole extending therethrough for receiving an intramedullary (IM) nail. The hole extends from the plantar surface of the body to the dorsal surface.
- In some embodiments, a calcaneal prosthesis comprises a single-piece body having a dorsal surface, an anterior surface, and a posterior end. The posterior end has a tuberosity. The anterior surface has a concavity shaped for receiving a cuboid bone or mid-foot bone(s). The dorsal surface includes a convex surface for engaging a talus bone or distal tibia. The unitary body has an integral intramedullary (IM) nail protruding from the dorsal surface.
- In some embodiments, a method of making a calcaneal prosthesis includes: collecting image data defining a first three-dimensional (3D) model of a first calcaneus of a patient; forming a second 3D model of a second calcaneus by computing a mirror image of the first 3D model about a sagittal plane; adding to the second 3D model at least one surface defining a hole that extends through the second calcaneus, the hole sized and shaped to receive an intramedullary nail; and fabricating the calcaneal prosthesis according to the second 3D model, using an additive manufacturing process.
-
FIG. 1 is a medial view of a left foot with a calcaneal prosthesis system. -
FIG. 2 is a medial isometric view of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 3 is a posterior view of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 4 is a lateral view of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 5 is an anterior view of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 6 is a superior view of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 7 is a medial view of a left foot with a variation of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 7A is an enlarged detail ofFIG. 7 . -
FIG. 8 is a medial isometric view of a single-piece calcaneal prosthesis system. -
FIG. 9 is a posterior view of the calcaneal prosthesis system ofFIG. 8 . -
FIG. 10 is a lateral view of the calcaneal prosthesis system ofFIG. 8 . -
FIG. 11 is an anterior view of the calcaneal prosthesis system ofFIG. 8 . -
FIG. 12 is a superior view of the calcaneal prosthesis system ofFIG. 8 . -
FIG. 13 is a posterior view of a variation of the calcaneal prosthesis system shown inFIG. 3 . -
FIG. 14 is a superior view of a variation of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 15 is a superior view of a variation of the calcaneal prosthesis system ofFIG. 14 . -
FIG. 16 is a superior view of a variation of the calcaneal prosthesis system ofFIG. 1 . -
FIG. 17 is a flow chart of a method of making the prosthesis ofFIG. 1 . - This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
- This disclosure describes a calcaneal prosthesis having one or more pre-drilled holes configured for receiving at least an intramedullary (IM) nail. This disclosure also describes a single-piece calcaneal prosthesis having an integrally formed IM nail extending from a dorsal surface of the calcaneal prosthesis. In cases where the patient's calcaneus has degraded, the calcaneal prosthesis provides a strong base for retaining the IM nail in position for fusing the calcaneal prosthesis, talus and tibia. Further, calcaneal prosthesis systems are provided.
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FIGS. 1-6 show a first embodiment of acalcaneal prosthesis 100.FIG. 1 is a schematic diagram of a left foot having acalcaneal prosthesis 100 andintramedullary nail 150 implanted therein. Thecalcaneal prosthesis 100 is configured to approximate the shape and function of a natural calcaneus, including thecalcaneal tuberosity 119. In some embodiments, theprosthesis 100 has a dorsal surface adapted to abut a resectedtalus 200 or resected tibia. In some embodiments, theprosthesis 100 has an anterior surface adapted to abut a resectedcuboid 202 and/or mid-foot bones. In the configuration shown inFIG. 1 , theIM nail 150 is inserted through thecalcaneal prosthesis 100, thetalus 200 and thetibia 204, for fusing thecalcaneal prosthesis 100, thetalus 200 and thetibia 204 together. In other embodiments, for a patient having a severely degraded talus, theprosthesis 100 can have an extended plantar-dorsal height, and theIM nail 150 is extended through thecalcaneal prosthesis 100, and directly into thetibia 204. - In some embodiments, a
calcaneal prosthesis system 180 may be employed including thecalcaneal prosthesis 100. In more detail, as shown inFIGS. 2-6 , thecalcaneal prosthesis system 180 comprises abody 110 having adorsal surface 112, aplantar surface 114, amedial surface 113, alateral surface 115, ananterior surface 116, and aposterior end 118. The anterior (A), medial (M) and dorsal (D) directions are shown inFIG. 2 . Theposterior end 118 has atuberosity 119. Thetuberosity 119 extends in an oblique direction relative to an anterior-posterior (A) direction of the body. - In some embodiments, the
anterior surface 116 has a concavity, convexity or flat surface shaped for receiving thecuboid bone 202 or mid-foot bone(s). For example, theanterior surface 116 can include aconcavity 116 c as shown inFIG. 2 . The concavity is shaped as an articulating surface for articulating motion with respect to the cuboid 202—or mid-foot bone(s) in a case where the surgeon makes a biplanar wedge cut to the mid-foot. In other embodiments described below with reference toFIGS. 14 and 15 , the anterior surface can include a trapezoid-shaped projection or a trapezoid-shaped recess, respectively, for abutting a resected cuboid (not shown) and/or mid-foot bone(s), not shown. - In the example of
FIGS. 2-6 , thedorsal surface 112 includes a convex surface for engaging atalus bone 200 and/or tibia. For example, because theexemplary prosthesis 100 is intended for use in a fusion surgery, thedorsal surface 112 can include a trapezoid-shapedconvexity 130 as shown inFIG. 2 , adapted to be received by a recess in a resected talus (not shown). The exemplary trapezoid-shapedconvexity 130 has the general form of a truncated pyramid, with trapezoidal surfaces on the medial, lateral, anterior and posterior sides, to facilitate an approach from any direction the surgeon may choose. In other embodiments described below with reference toFIG. 13 , the dorsal surface can include a trapezoid-shaped recess, for abutting a corresponding projection of a resected talus (not shown). In other embodiments, a concave or flat surface can be substituted for the convex surface on thedorsal surface 112 of the body. Further, convex surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a protuberance; concave surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a recess. - The
body 110 has a pre-formed surface defining ahole 104 therethrough for receiving anIM nail 150. In particular, the previously formedhole 104 may be pre-drilled, or pre-made by forging, casting and/or machining. In other embodiments, the surfaces defining theholes 104 are formed as part of an additive manufacturing (AM) process, such as 3D printing or direct metal laser sintering (DMLS) as discussed below. If an AM process is used, theprosthesis 100 is formed as a plurality of stacked monolayers, and holes are formed by voids at selected locations within the monolayers. The surfaces definingpre-formed hole 104 may be pre-planned using patient specific planning. In some embodiments, the detailed shape of the non-degraded calcaneus is determined (e.g., by CT scan), a mirror image of the shape is formed about the mid-sagittal plane, and an AM process is used to construct the prosthesis according to the mirror image. A patient-specific manufacturing method for forming theprosthesis 100 is described below in the discussion ofFIG. 17 . - In other embodiments, one or more “generic” calcaneus implants can be provided with multiple sizes. For example, after removing the degraded calcaneal tissue, the surgeon can insert one or more calcaneal prosthesis trials (not shown) for purpose of finding the standard size calcaneal prosthesis that most closely fits the foot anatomy of the patient. The surgeon then implants a calcaneal prosthesis having a size corresponding to the most closely-fitting calcaneal prosthesis trial. If the trial method is used, the surgeon can fit the calcaneal prosthesis without scanning the healthy calcaneus of the opposite foot.
- The
hole 104 extends from theplantar surface 114 of thebody 110 to thedorsal surface 112 of thebody 110. In the case where the prosthesis is molded or formed by additive manufacturing (e.g., 3D printing or direct metal laser sintering), thesurface defining hole 104 is formed at the same time the prosthesis is formed. In the case where theprosthesis 100 is formed by machining, thesurface defining hole 104 may be formed at any time point before, during or after the machining process. Forming thesurface defining hole 104 at the beginning of machining provides more options for stabilizing the piece of material from which the prosthesis is formed during the remainder of the machining. Forming thesurface defining hole 104 during fabrication of thecalcaneal prosthesis 100 reduces the length of the surgery preparation and avoids the difficulty of the surgeon drilling an aligned hole in the irregularly shapedcalcaneal prosthesis 100. - A plurality of fastener openings (e.g., screw-receiving openings) penetrate the
body 110 from themedial surface 113,lateral surface 115,anterior surface 116 and/orposterior end 118. Thefastener openings calcaneal prosthesis 100 to thehole 104. In some embodiments, theIM nail 150 has a set screw that can be advanced within the nail to compress the joint. In some embodiments, the surgeon can implant bone screws into thecalcaneal prosthesis 100 and into aligned screw-receiving holes in the IM nail, to stabilize the IM nail and prevent it from loosening or moving.Prosthesis 100 can also have surfaces defining additional fixation holes from medial, lateral, or posterior side of the calcaneal to fuse calcaneal to cuboid and/or mid-foot bones. For example,FIGS. 2-6 show afastener opening 106 on themedial surface 113 and afastener opening 105 on thelateral surface 115. The at least one fastener opening can be oriented at an oblique angle relative to the hole. These are just exemplary locations and orientations. The fastener opening can be provided at different locations (not shown). Thefastener openings - The
body 110 can have one ormore openings 120 for receiving k-wires for external fixation. The example inFIGS. 1-6 has twoopenings 120, but other embodiments can have any number of openings for external fixation. Theopenings 120 can extend part way into thebody 110 or extend from one (e.g., lateral) side to the opposite (e.g., medial) side as shown. The k-wires can be attached to an external fixation device, such as a circular fixator or the like (not shown). - The
calcaneal prosthesis system 180 further comprises an intramedullary (IM)nail 150 shaped to extend through thehole 104. TheIM nail 150 has at least oneaperture fastener opening body 110. - The
IM nail 150 comprises a material such as titanium, a titanium alloy (e.g., Ti 6Al-4V) or stainless steel, or cobalt chrome (CoCr). - The
IM nail 150 has an elongated shape. In some embodiments, the IM nail has a first diameter D1 along its entire length, as shown inFIG. 2 . In other embodiments (as discussed below with reference toFIG. 7 , the IM nail has a stop to prevent the IM nail from moving toward thetibia 204 when pressure is applied to the foot. - The exemplary
calcaneal prosthesis system 180 allows implantation of an IM nail, even in the case where the patient's calcaneus is deteriorated, such as in the case of Charcot disease. The surgeon can replace the calcaneus with thecalcaneus prosthesis 100 and then insert theIM nail 150. Thecalcaneus prosthesis 100 provides a strong, aligned implant for securing theIM nail 150. The previously formedsurface defining hole 104 andfastener openings calcaneus prosthesis 100 and avoid alignment errors due to incorrect drilling by the surgeon. - Although
FIGS. 1-6 show acalcaneal prosthesis system 180 for a left foot, a calcaneal prosthesis for the right foot (not shown) can share the same design elements arranged as a mirror image ofcalcaneal prosthesis system 180 with respect to the mid-sagittal plane. - In some embodiments, a method for implanting the
calcaneal prosthesis system 180 ofFIGS. 1-6 comprises implanting acalcaneal prosthesis 100 through a medial incision, a lateral incision, an anterior incision, or a posterior incision in a foot. - For example, a method of implanting the
calcaneal prosthesis system 180 can include making an incision for inserting thecalcaneal prosthesis 100 from a desired side (e.g., an anterior approach). Depending on the quality of thetalar bone 200 and the configuration of the dorsal surface of thecalcaneal prosthesis 100, the surgeon may resect thetalus 200 to include a recess or a protuberance. The surgeon may place pins in thetalus 200 and/orcuboid 202 for aligning thecalcaneal prosthesis 100 during implantation. - The
calcaneal prosthesis 100 is inserted into the wound site. Thecalcaneal prosthesis 100 has apre-planned hole 104 therethrough. Thehole 104 extends from aplantar surface 114 of the calcaneal prosthesis to adorsal surface 112 of thecalcaneal prosthesis 100. The surgeon drills to extend the hole for theIM nail 150 through thetalus 200 andtibia 204 from a plantar approach. Then theIM nail 150 is inserted through a plantar incision in the foot and through thehole 104 of thecalcaneal prosthesis 100, through thetalus 200 and into thetibia 204. The surgeon inserts one or more bone screws through afastener opening medial side 113,lateral side 115,anterior side 116, orposterior side 118 of thecalcaneal prosthesis 100 and into a corresponding aperture in theIM nail 150. The fasteners (e.g., bone screws) are inserted through thecalcaneal prosthesis 100 and into theapertures IM nail 150 to lock theIM nail 150 in place. For example, the surgeon may insert three screws: a transverse calcaneal screw, a posterior calcaneal screw, and subtalar screw (if the patient's talus is intact). The surgeon also inserts one or more bone screws through thetibia 204 and into theIM nail 150. Thecalcaneal prosthesis system 180 can be advantageous if the surgeon wants to use an anterior, posterior, lateral or medial approach for inserting thecalcaneal prosthesis 100. -
FIG. 7 shows an embodiment of a calcaneal prosthesis system 780 in which theIM nail 750 has ashoulder 751, and thecalcaneal prosthesis 700 has acorresponding stop 752 for limiting a depth of insertion of theIM nail 750.FIG. 7A is an enlarged detail ofFIG. 7 , showing theshoulder 751 ofIM nail 750 abutting thestop 752 within the hole. InFIG. 7 , theIM nail 750 has a first portion 753 (e.g., a dorsal portion) with a first diameter D1, and a second portion 754 (e.g., plantar portion) with a second diameter D2 different from the first diameter D1. The surface defining the hole in thebody 700 has afirst part 704 sized to receive thefirst portion 753 of theIM nail 750 and asecond part 705 sized to receive thesecond portion 754 of theIM nail 750. Thestop 752 is located at the interface between thefirst part 704 and thesecond part 705. When theIM nail 750 is inserted through thecalcaneal prosthesis 700 and thetalus 200, theshoulder 751 of theIM nail 750 abuts thestop 752 and prevents theIM nail 750 from traveling further into thetibia 204. Thestop 752 can be formed by acounter bore 705 in the plantar surface of thecalcaneal prosthesis 700. In some embodiments, as shown inFIG. 7 thestop 752 is located within thecalcaneal prosthesis 700. - Although
IM nail 750 has an increase in diameter from D1 to D2 where thefirst portion 753 meets thesecond portion 754, this is not a requirement. In other embodiments (not shown), the IM nail has a gradual taper from the first diameter D1 to the second diameter D2. Thecalcaneal prosthesis 700 can have a corresponding gradual taper from the first diameter D1 to the second diameter D2. The tapered portion (not shown) of the surface defining the hole in the calcaneal prosthesis can act as the stop. - In another embodiment (not shown), the
second portion 754 of theIM nail 750 extends from the plantar surface of the calcaneal prosthesis to the dorsal surface of the calcaneal prosthesis. Thesurface defining hole 705 has the larger diameter D2 for the entire distance from the plantar surface of thecalcaneal prosthesis 700 to the dorsal surface of the calcaneal prosthesis. Thesurface defining hole 706 in thetalus 200 andtibia 204 has the smaller diameter D1, and the cortical bone of thetalus 200 provides thestop 752. - The method for implanting the
calcaneal prosthesis 700 is similar to the method described above for implanting thecalcaneal prosthesis system 180 ofFIG. 1 As noted above, theIM nail 750 has afirst portion 753 with a first diameter D1, asecond portion 754 with a second diameter D2 larger than the first diameter D1, and ashoulder 751 at an interface between thefirst portion 753 and thesecond portion 754. The surface defining hole in thecalcaneal prosthesis 700 has afirst part 704 sized to receive thefirst portion 753 of theIM nail 750 and asecond part 705 sized to receive thesecond portion 754 of theIM nail 750. The step of inserting theIM nail 750 into thehole IM nail 750 until theshoulder 751 of theIM nail 750 abuts thestop 752 of theopening 705. -
FIGS. 8-12 show an embodiment of a single-piececalcaneal prosthesis 800 for a left foot. Except where expressly indicated below, the shape of theprosthesis 800 can be the same as the shape of theprosthesis 100 ofFIGS. 1-6 . -
FIG. 8 is a schematic diagram of a left foot having a monolithiccalcaneal prosthesis 800 having an integralintramedullary nail 850 formed of a single piece of material. Thecalcaneal prosthesis 800 is configured to approximate the shape and function of a natural calcaneus, including thecalcaneal tuberosity 819. In some embodiments, theprosthesis 800 has a dorsal surface adapted to abut a resectedtalus 200 or resectedtibia 204. In some embodiments, theprosthesis 800 has an anterior surface adapted to abut a resectedcuboid 202 and/or mid-foot bones. In the configuration shown inFIG. 8 , theIM nail 850 is configured to be inserted through thetalus 200 and thetibia 204, for fusing thecalcaneal prosthesis 800, thetalus 200 and thetibia 204 together. In other embodiments, for a patient having a severely degraded talus, theprosthesis 800 can have an extended plantar-dorsal height, and theIM nail 850 is configured to extend directly into thetibia 204. - In more detail, as shown in
FIGS. 9-12 , the calcaneal prosthesis system 880 comprises abody 810 having adorsal surface 812, aplantar surface 814, amedial surface 813, alateral surface 815, ananterior surface 816, and aposterior end 818. The anterior (A), medial (M) and dorsal (D) directions are shown inFIG. 8 . Theposterior end 818 has atuberosity 819. Thetuberosity 819 extends in an oblique direction relative to an anterior-posterior (A) direction of the body. - In some embodiments, the
anterior surface 816 has a concavity, convexity or flat surface shaped for receiving thecuboid bone 202 or mid-foot bone(s). For example, theanterior surface 816 can include aconcavity 816 c as shown inFIG. 8 . The concavity is shaped as an articulating surface for articulating motion with respect to the cuboid 202 (or mid-foot bone(s) in a case where the surgeon makes a biplanar wedge cut to the mid-foot). In other embodiments described below with reference toFIGS. 14 and 15 , the anterior surface can include a trapezoid-shaped projection or a trapezoid-shaped recess, respectively, for abutting a resected cuboid (not shown) and/or mid-foot bone(s), not shown. - In the example of
FIGS. 8-12 , thedorsal surface 812 includes a convex surface for engaging atalus bone 200 and/or tibia. For example, because theexemplary prosthesis 800 is intended for use in a fusion surgery, thedorsal surface 812 can include a trapezoid-shapedconvexity 830 as shown inFIG. 8 , adapted to be received by a recess in a resected talus (not shown). The exemplary trapezoid-shapedconvexity 830 has the general form of a truncated pyramid, with trapezoidal surfaces on the medial, lateral, anterior and posterior sides, to facilitate an approach from any direction the surgeon may choose. In other embodiments described below with reference toFIG. 13 , the dorsal surface can include a trapezoid-shaped recess, for abutting a corresponding projection of a resected talus (not shown). In other embodiments, a concave or flat surface can be substituted for the convex surface on thedorsal surface 812 of the body. Further, convex surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a protuberance; concave surfaces can be curved or can comprise combinations of flat and/or curved surfaces that form a recess. - The
body 810 andIM nail 850 may be pre-drilled, or pre-made by forging, casting and/or machining. In other embodiments, thebody 810 andIM nail 850 are formed as part of an additive manufacturing (AM) process, such as 3D printing or direct metal laser sintering (DMLS) as discussed below. If an AM process is used, theprosthesis 800 is formed as a plurality of stacked monolayers, and the k-wire holes 820 are formed by voids at selected locations within the monolayers. Thepre-formed holes 820 may be pre-planned using patient specific planning. For example, thecalcaneus prosthesis 800 can be a patient-specific prosthesis designed as a mirror image of a non-degraded calcaneus of the patient's opposite foot. The location and angulation of the implant holes and IM nail hole can be designed using a three-dimensional model to ensure that the fasteners and IM nail do not extend into one or more predetermined sections of a corresponding three-dimensional model of the patient's tissue, as determined by X-ray imagery. - In the case where the prosthesis is molded or formed by additive manufacturing (e.g., 3D printing or direct metal laser sintering), the
IM nail 850 is formed at the same time thebody 810 is formed. In the case where theprosthesis 800 is formed by machining, theIM nail 850 may be formed at any time point before, during or after machining thebody 810. Forming the surface defining hole 804 at the beginning of machining provides more options for stabilizing the piece of material from which the prosthesis is formed during the remainder of the machining. Forming theIM nail 850 during fabrication of thecalcaneal prosthesis 800 reduces the length of the surgery preparation and avoids the difficulty of the surgeon drilling an aligned hole in the irregularly shapedcalcaneal prosthesis 800. - In some embodiments, the
IM nail 850 has a set screw that can be advanced within the nail to compress the joint.Prosthesis 800 can also have additional surfaces defining fixation holes from medial, lateral, or posterior side of thecalcaneal prosthesis 800 to fusecalcaneal prosthesis 800 to cuboid and/or mid-foot bones. The fastener opening can be provided at different locations (not shown). The fastener openings can be oriented at a variety of different angles. Additional fastener openings can be included, and the number of fastener openings is not limited to two. For example, some embodiments also have additional surfaces defining fixation holes from medial, lateral, or posterior side of the calcaneal to fuse calcaneal to cuboid and/or mid-foot bones. - The
body 810 can have one ormore openings 820 for receiving k-wires for external fixation. The example inFIGS. 8-12 has twoopenings 820, but other embodiments can have any number of openings for external fixation. Theopenings 820 can extend part way into thebody 810 or extend from one (e.g., lateral) side to the opposite (e.g., medial) side as shown. The k-wires can be attached to an external fixation device, such as a circular fixator or the like (not shown). - The
IM nail 850 has at least oneaperture - The
IM nail 850 has an elongated shape. In some embodiments, the IM nail has a first diameter D1 along its entire length, as shown inFIG. 8 . In other embodiments (as discussed above with reference toFIG. 7 , the IM nail has a stop to prevent the IM nail from moving toward thetibia 204 when pressure is applied to the foot. - Although
FIGS. 8-12 show a calcaneal prosthesis system 880 for a left foot, a calcaneal prosthesis for the right foot (not shown) can share the same design elements arranged as a mirror image of calcaneal prosthesis system 880 with respect to the mid-sagittal plane. - The single-piece
calcaneal prosthesis 800 comprises a unitary (i.e., single-piece, monolithic)body 810 having adorsal surface 812, aplantar surface 814, ananterior surface 816, and aposterior end 818. Theposterior end 818 has atuberosity 819. Theanterior surface 816 can have aconcavity 816 c shaped for receiving acuboid bone 202 or mid-foot bone(s). In other embodiments, a convex or flat surface can be substituted for theconcavity 816 c. Thedorsal surface 812 can include aconvex surface 830 for engaging atalus bone 200 and/or distal tibia. In other embodiments, a concave or flat surface can be substituted for theconvexity 830. The unitary body has anintegral IM nail 850 protruding from thedorsal surface 812. In the example ofFIG. 8 , the integral IM nail protrudes from theconvex surface 830 of thedorsal surface 812. In other embodiments, a concave or flat surface can be substituted for theconvex surface 830. Theintegral IM nail 850 has at least oneaperture body 810. The surgeon can insert fasteners (e.g., bone screws) through the cortical bone of thetibia 204 and/ortalus 200 and into theapertures IM nail 850. In some embodiments, theapertures longitudinal axis 840 of theIM nail 850. The body can have one ormore openings 820 for receiving k-wires for external fixation. - The single-
piece prosthesis 800 can eliminate separate installation steps for theIM nail 850, and eliminate fasteners (e.g., bone screws) for fixing theIM nail 850 to the calcaneal prosthesis. Thehole 104 is omitted from thecalcaneal prosthesis 800, because theIM nail 850 is not a separate piece and is not inserted into a hole in thecalcaneal prosthesis 800. Thefastener openings calcaneal prosthesis 100 can also be omitted, because fasteners are not used to lock the IM nail to the calcaneal prosthesis. - The single-piece construction of
prosthesis 800 eliminates the separate steps of inserting thecalcaneal prosthesis 100 and then inserting theIM nail 150, as described above with reference toFIGS. 1-7 . The single-piece prosthesis is implanted from a plantar approach, and thus involves a larger plantar incision than thecalcaneal prosthesis system 180. The surgeon makes an incision in the plantar surface of the foot. Any remaining calcaneal bone is removed. The surgeon drills a plantar-dorsal hole through thetalus 200 and into the longitudinal axis of thetibia 204. Thetalus 200 is resected (via lateral or medial approach) to receive the dorsal convexity (or fit into a dorsal concavity) of the calcaneal prosthesis. Theprosthesis 800 is inserted nail-first into the wound via plantar approach, and theIM nail 850 is inserted through thetalus 200 and into thetibia 204. -
FIG. 13 shows acalcaneal prosthesis system 1300 including acalcaneal prosthesis 1310 that is a variation of thecalcaneal prosthesis 100.Calcaneal prosthesis 1310 has adorsal surface 1312, a plantar surface 1314, an anterior surface (not shown), amedial surface 1313, alateral surface 1315, and aposterior end 1318. Theposterior end 1318 has atuberosity 1319. The anterior surface can have a concavity shaped for receiving thecuboid bone 202 and/or mid-foot bone(s). Thecalcaneal prosthesis 1310 can be the same as thecalcaneal prosthesis 100 except that the anterior surface 1316 of thecalcaneal prosthesis 1310 has a concave recess 1330 (e.g., a trapezoid-shaped recess) instead of theconvexity 130 ofcalcaneal prosthesis 100. Theconcave recess 1330 of thecalcaneal prosthesis 1310 is configured to receive a resected talus having a trapezoid shaped protuberance. In all other respects, thecalcaneal prosthesis 1300 can have the same configuration as thecalcaneal prosthesis 100. For brevity, descriptions of the common features ofcalcaneal prosthesis 1310 andcalcaneal prosthesis 100 are not repeated. -
FIG. 14 shows acalcaneal prosthesis system 1400 including acalcaneal prosthesis 1410 that is a variation of thecalcaneal prosthesis 100.Calcaneal prosthesis 1410 has adorsal surface 1412, a plantar surface (not shown), amedial surface 1413, alateral surface 1415, and aposterior end 1418. Theposterior end 1418 has a tuberosity (not shown). Thecalcaneal prosthesis 1410 differs from thecalcaneal prosthesis 100 in that theanterior surface 1416 ofcalcaneal prosthesis 1410 can have a convex protuberance for interfacing to a resectedcuboid bone 202 having a trapezoidal recess. Theanterior surface 1416 ofcalcaneal prosthesis 1410 can have a trapezoidal shape. The convex protuberance can provide added stability in the event the surgeon is going to fuse the cuboid 202 to thecalcaneal prosthesis 1410. In all other respects, thecalcaneal prosthesis 1410 can have the same configuration as thecalcaneal prosthesis 100. For brevity, descriptions of the common features ofcalcaneal prosthesis 1410 andcalcaneal prosthesis 100 are not repeated. -
FIG. 15 shows acalcaneal prosthesis system 1500 including acalcaneal prosthesis 1510 that is a variation of thecalcaneal prosthesis 100.Calcaneal prosthesis 1510 has adorsal surface 1512, a plantar surface (not shown), amedial surface 1513, alateral surface 1515, and aposterior end 1518. Theposterior end 1518 has a tuberosity (not shown). Thecalcaneal prosthesis 1510 differs from thecalcaneal prosthesis 100 in that theanterior surface 1516 ofcalcaneal prosthesis 1510 can have a concave recess for interfacing to a resectedcuboid bone 202 having a trapezoidal protuberance. Theanterior surface 1516 ofcalcaneal prosthesis 1510 can have a trapezoidal shape. The concave recess can provide added stability in the event the surgeon is going to fuse the cuboid 202 to thecalcaneal prosthesis 1510. In some embodiments, thecalcaneal prosthesis 1510 has surfaces defining additional holes (not shown) configured to receive fixation screws from through the calcaneal prosthesis and into the cuboid or mid-foot bones. In all other respects, thecalcaneal prosthesis 1510 can have the same configuration as thecalcaneal prosthesis 100. For brevity, descriptions of the common features ofcalcaneal prosthesis 1510 andcalcaneal prosthesis 100 are not repeated. -
FIG. 16 shows acalcaneal prosthesis system 1600 including acalcaneal prosthesis 1610 that is a variation of thecalcaneal prosthesis 100.Calcaneal prosthesis 1610 has adorsal surface 1612, a plantar surface (not shown), amedial surface 1613, a lateral surface 1615, ananterior surface 1616, and aposterior end 1618. The external shape ofcalcaneal prosthesis 1610 can be the same as the external surface ofcalcaneal prosthesis 100. For brevity, a description of the external shape of the common features is not repeated. Theposterior end 1618 has a tuberosity (not shown). Thecalcaneal prosthesis 1610 differs from thecalcaneal prosthesis 100 in that the internal structure ofcalcaneal prosthesis 1610 has a lower average density thancalcaneal prosthesis 100.Calcaneal prosthesis 1610 can be substantially hollow to reduce weight, and can optionally includestruts tube 1655 extending from the plantar surface (not shown) to theconvex portion 1630 ofdorsal surface 1612. Thestruts tube 1655 is configured to receive theIM nail 150. In all other respects, thecalcaneal prosthesis 1610 can have the same configuration as thecalcaneal prosthesis 100. - In some embodiments, the
calcaneal prosthesis 1610 comprises a porous material throughout the prosthesis. In some embodiments, the interior of thecalcaneal prosthesis 1610 has a porous material with a first density and one ormore struts struts calcaneal prosthesis 1610 comprises the porous material. The porous material can have the same composition and a lower density than thestruts - In the embodiments described above with reference to
FIGS. 1-16 , thebody 110 comprises a biocompatible material from the group consisting of metals such as titanium, stainless steel, absorbable magnesium, metal alloys; polymers such as polyethylene, ultra-high molecular weight polyethylene (UHMWPE), polyether ether ketone (PEEK), Polyetherketone (PEK), absorbable and non-absorbable polymers and copolymers; ceramics such as pyrocarbon; and combinations thereof. stainless steel. Further thebody 110 may be coated with materials what may enhance biocompatibility such as, for example, plasma spray, hyaluronic acid, anti-microbial natural and synthetic polymers (e.g., vitamin E). - In the embodiments described above with reference to
FIGS. 1-16 , thecalcaneal prosthesis 100 can be formed by forging, casting, machining or direct metal laser sintering (DMLS). DMLS is an additive manufacturing (AM) process by which products can be printed using a laser or e-beam joining sequential layers of powder metal (e.g., Ti6Al4V or CoCr or Stainless Steel, for example) under automated computer control. Using DMLS, thecalcaneal prosthesis 100 can be formed as a highly porous structure. Highly porous structures also provide good bone in-growth properties. Alternatively, thecalcaneal prosthesis 100 can be formed as a continuous solid, having a rough surface or a highly porous layer at the surface. - For example, the
calcaneal prosthesis 100 can have a porous surface layer with a thickness in a range from 0.01 inch to 0.1 inch. In some embodiments, the porous surface layer has a thickness in a range from 0.03 inch to 0.07 inch. In one example, the porous surface layer has a thickness in a range from 0.04 inch to 0.06 inch. In some embodiments, a first portion of the surface area of thecalcaneal prosthesis 100 is porous, and a second portion of the surface area of thecalcaneal prosthesis 100 is non-porous. For example, in the embodiment ofFIGS. 2-6 , thecalcaneal prosthesis 100 can have rough surface or porous layer at thedorsal surface 112 of thebody 110, and/or at theanterior surface 116 of thebody 110, with a smooth surface on the remaining sides. This is a non-exclusive example, and the calcaneal prosthesis can have other combinations of smooth surface(s), rough surface(s) and surfaces having a porous layer. -
FIG. 17 is a flow chart of a method of making a calcaneal prosthesis as shown inFIGS. 1-16 . This method assumes that the patient's feet are symmetrical or nearly-symmetrical about the mid-sagittal plane, except for the deteriorated calcaneus in one foot. - At
step 1702, a set of image data are collected to define a first three-dimensional (3D) model of a first calcaneus (the healthy or non-degraded calcaneus) of a patient. The images can be collected by a tomography method, such as X-ray computed tomography (CT) or magnetic resonance imaging (MRI). A series of two-dimensional (2D) images (slices) of the patient's healthy calcaneus are collected. The images also include the talus and tibia. The 3D model is constructed from the 2D images, using a Radon transform, for example. - At
step 1704, a second 3D model of a second calcaneus is formed by computing a mirror image of the first 3D model about a sagittal plane. - At
step 1706, at least one surface defining a hole is added to the second 3D model. The hole extends through the second calcaneus, and is sized and shaped to receive an intramedullary nail. The hole is positioned so as to lie along the longitudinal axis of the tibia. - At
step 1710, fastener holes and/or guide wire holes are added to the 3D model. The location and angulation of the fastener holes and/or guide wire holes are adjusted such that the fasteners, guide wire holes and IM nail do not interfere with each other and do not contact specific tissue portions such as nerves. The location and angulation of the fastener holes, guide wire holes and IM nail hole can be designed using a three-dimensional model to ensure that the fasteners, guide wires (e.g., k-wires) and IM nail do not extend into one or more predetermined sections of a corresponding three-dimensional model of the patient's tissue, as determined by tomography. - At
step 1710, the calcaneal prosthesis is fabricated according to the second 3D model, using an additive manufacturing process. For example, thecalcaneus prosthesis 100 can be a patient-specific prosthesis designed as a mirror image of a non-degraded calcaneus of the patient's opposite foot. - Although the subject matter has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art.
Claims (20)
1. A calcaneal prosthesis, comprising:
a single-piece body having a dorsal surface, an anterior surface, and a posterior end,
the posterior end having a tuberosity,
the anterior surface having a concavity shaped for receiving a cuboid bone or mid-foot bone,
the dorsal surface including a convex surface for engaging a talus bone or distal tibia,
the single-piece body having an integral intramedullary (IM) nail protruding from the dorsal surface.
2. The calcaneal prosthesis of claim 1 , wherein the IM nail has at least one aperture at an end of the IM nail opposite from the body.
3. The calcaneal prosthesis of claim 2 , wherein the at least one aperture is to configured to receive a fastener oriented at an oblique angle relative to a longitudinal axis of the IM nail.
4. The calcaneal prosthesis of claim 1 , wherein the convex surface has a trapezoidal shape.
5. The calcaneal prosthesis of claim 1 , wherein the tuberosity extends in an oblique direction relative to an anterior-posterior direction of the body.
6. The calcaneal prosthesis of claim 1 , wherein the calcaneal prosthesis is manufactured via an additive manufacturing technique.
7. A prosthesis, comprising:
a body including a dorsal surface, a planar surface, a medial surface, a lateral surface, an anterior surface, an a posterior end having a tuberosity that approximates a shape of a calcaneal tuberosity; and
an intramedullary nail extending from the dorsal surface of the body,
wherein the intramedullary nail is integrally formed with the body.
8. The prosthesis of claim 7 , wherein the tuberosity extends in an oblique direction relative to an anterior-posterior direction of the body.
9. The prosthesis of claim 7 , wherein the anterior surface includes a trapezoid-shaped projection.
10. The prosthesis of claim 7 , wherein the anterior surface defines a trapezoid-shaped recess.
11. The prosthesis of claim 7 , wherein the dorsal surface includes a convex surface, and wherein the intramedullary nail extends from the convex surface.
12. The prosthesis of claim 11 , wherein the convex surface has a trapezoidal shape.
13. The prosthesis of claim 12 , wherein the body defines an opening sized and configured to receive a fixation device.
14. The prosthesis of claim 13 , wherein the intramedullary nail defines at least one aperture sized and configured to receive a fastener.
15. The prosthesis of claim 12 , wherein the intramedullary nail defines at least one aperture sized and configured to receive a fastener.
16. The prosthesis of claim 7 , wherein the intramedullary nail has an elongated shape having a constant diameter along its length.
17. The prosthesis of claim 7 , wherein the intramedullary nail includes a stop along its length.
18. A method, comprising:
collecting image data defining a first three-dimensional model of a first calcaneus of a patient;
forming a second three-dimensional model of a second calcaneus by computing a mirror image of the first three-dimensional model about a sagittal plane; and
fabricating a calcaneal prosthesis having a body and an intramedullary nail according to the second three-dimensional model,
wherein the intramedullary nail is integrally formed with the body.
19. The method of claim 18 , wherein the calcaneal prosthesis is formed using an additive manufacturing process.
20. The method of claim 18 , further comprising adding at least one hole to the second three-dimensional model, the at least one hole sized and configured to a fixation device.
Priority Applications (2)
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US17/302,103 US20210236295A1 (en) | 2017-06-13 | 2021-04-23 | Calcaneal prosthesis and method of forming the same |
US18/470,517 US20240000579A1 (en) | 2017-06-13 | 2023-09-20 | Calcaneal prosthesis |
Applications Claiming Priority (3)
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PCT/US2017/037209 WO2018231202A1 (en) | 2017-06-13 | 2017-06-13 | Calcaneal prosthesis |
US201916495925A | 2019-09-20 | 2019-09-20 | |
US17/302,103 US20210236295A1 (en) | 2017-06-13 | 2021-04-23 | Calcaneal prosthesis and method of forming the same |
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PCT/US2017/037209 Division WO2018231202A1 (en) | 2017-06-13 | 2017-06-13 | Calcaneal prosthesis |
US16/495,925 Division US11096793B2 (en) | 2017-06-13 | 2017-06-13 | Calcaneal prosthesis |
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US18/470,517 Continuation US20240000579A1 (en) | 2017-06-13 | 2023-09-20 | Calcaneal prosthesis |
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US20210236295A1 true US20210236295A1 (en) | 2021-08-05 |
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US16/495,925 Active US11096793B2 (en) | 2017-06-13 | 2017-06-13 | Calcaneal prosthesis |
US17/302,103 Abandoned US20210236295A1 (en) | 2017-06-13 | 2021-04-23 | Calcaneal prosthesis and method of forming the same |
US18/470,517 Pending US20240000579A1 (en) | 2017-06-13 | 2023-09-20 | Calcaneal prosthesis |
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US16/495,925 Active US11096793B2 (en) | 2017-06-13 | 2017-06-13 | Calcaneal prosthesis |
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EP (1) | EP3582725B1 (en) |
AU (1) | AU2017418982B2 (en) |
CA (1) | CA3057600C (en) |
WO (1) | WO2018231202A1 (en) |
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US20210322071A1 (en) * | 2020-04-15 | 2021-10-21 | David GITLIN | Bone fixation system |
CN112075989B (en) * | 2020-09-29 | 2024-07-02 | 华侨大学 | Regular polyhedron porous filling structure calcaneus prosthesis and optimal design method thereof |
KR102413390B1 (en) * | 2020-10-06 | 2022-06-30 | 주식회사 코렌텍 | Customized Talus Implant |
CN113367857B (en) * | 2021-05-22 | 2022-11-01 | 北京力达康科技有限公司 | Calcaneus talus prosthesis |
CN113367856B (en) * | 2021-05-22 | 2022-10-21 | 北京力达康科技有限公司 | Calcaneus prosthesis |
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FR2895664B1 (en) | 2005-12-29 | 2008-10-10 | Fournitures Hospitalieres Ind | TRANSCALCANEUM SCREW FOR ARTHRODESIS OF ANKLE |
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WO2013181358A1 (en) * | 2012-05-30 | 2013-12-05 | Acumed Llc | Articulated intramedullary nail |
RU2515391C1 (en) | 2013-01-30 | 2014-05-10 | Общество с ограниченной ответственностью "Медико-инженерный центр сплавов с памятью формы" | Calcaneal implant |
US10016811B2 (en) * | 2013-08-09 | 2018-07-10 | David J. Neal | Orthopedic implants and methods of manufacturing orthopedic implants |
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CN106691635B (en) | 2016-12-30 | 2019-12-03 | 北京爱康宜诚医疗器材有限公司 | Calcaneum prosthese |
-
2017
- 2017-06-13 EP EP17913516.5A patent/EP3582725B1/en active Active
- 2017-06-13 US US16/495,925 patent/US11096793B2/en active Active
- 2017-06-13 CA CA3057600A patent/CA3057600C/en active Active
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2023
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Publication number | Priority date | Publication date | Assignee | Title |
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US20020103488A1 (en) * | 2000-04-10 | 2002-08-01 | Lower Jerry L. | Intramedullary nail with snap-in window |
US20090062796A1 (en) * | 2006-05-10 | 2009-03-05 | Concepts In Medicine, Llc | Modular, blade-rod, intramedullary fixation device |
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US20200129302A1 (en) | 2020-04-30 |
US11096793B2 (en) | 2021-08-24 |
EP3582725A1 (en) | 2019-12-25 |
AU2017418982B2 (en) | 2020-03-12 |
EP3582725B1 (en) | 2023-06-21 |
CA3057600A1 (en) | 2018-12-20 |
AU2017418982A1 (en) | 2019-10-10 |
EP3582725A4 (en) | 2020-12-09 |
WO2018231202A1 (en) | 2018-12-20 |
CA3057600C (en) | 2021-12-28 |
US20240000579A1 (en) | 2024-01-04 |
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