Abstract: The present teachings generally include a hand-held surgical robotic system for supporting a surgical tool, the handheld surgical robotic system comprising a hand-held portion, a tool support movably coupled to the hand-held portion, the tool support configured to support a surgical tool, a plurality of actuators operatively interconnecting the tool support and the hand-held portion, the plurality of actuators configured to move the tool support relative to the hand-held portion in a plurality of degrees of freedom, a controller in communication with the plurality of actuators and a flexible circuit connecting the controller with each of the plurality of actuators, such that the flexible circuits are arranged to maintain the connection between the controller and the plurality actuators and/or an input module while the tool support is moved in the plurality of degrees of freedom relative to the hand-held portion.

Abstract: A surgical system includes a tracking system configured to intraoperatively track relative positions of bones of a joint, a user interface configured to obtain a user input indicating a post-operative value for the joint, and a computer programmed to generate, based on the relative positions of the bones and the post-operative value, a planned orientation for an implant to be implanted in the joint, and to generate a surgical plan based on the planned orientation for the implant.

Abstract: Robotic surgical systems and methods for guiding a tool along a path using hybrid automated/manual control. A manipulator supports a surgical tool and a sensor measures forces/torques applied to the tool. A control system commands the manipulator to perform an automated advancement of the tool along a predetermined tool path in a first path direction and according to a predetermined feed rate. During the automated advancement, an input is received from the sensor in response to user applied forces/torques to the tool. The control system evaluates an effect of the sensor input on the automated advancement of the tool to determine an effective feed rate and an effective path direction for the tool with respect to the tool path. The control system determines a commanded action for the manipulator and the tool with respect to the tool path based on the effective feed rate and effective path direction.

Abstract: A method of operating a surgical system includes controlling a robotic arm in a first control mode in which the robotic arm constrains movement of a surgical tool coupled to the robotic arm to a virtual geometry correlated with an anatomical feature, switching, responsive to the surgical tool crossing an exit boundary, from the first control mode to a second control mode, and controlling the robotic arm in the second control mode in which movement of the surgical tool is unconstrained by the virtual geometry.

Abstract: A method of smoothing a surface mesh includes determining first angles between a first direction and vectors normal to a plurality of faces defined in the surface mesh, determining a set of artifact vertices by including a first vertex of the surface mesh in the set of artifact vertices responsive to the first angles associated with faces adjacent to the first vertex satisfying a first condition, calculating a weighted value for a second vertex of the surface mesh based on a distance from the second vertex to a nearest artifact vertex in the set of artifact vertices, and generating a smoothed surface mesh by using the weighted value in a smoothing algorithm applied to the surface mesh.

Abstract: Systems, methods and computer-program products are provided for aiding in positioning between a surgical object and a machine vision camera in a surgical environment. The machine vision camera senses a position and orientation of a surgical object in its field of view. Controller(s) virtually define a zone within the field of view that indicates a range of acceptable positions for the surgical object relative to a position of the machine vision camera. The controller(s) obtain an acceptable orientation range for the surgical object relative to an orientation of the machine vision camera. The controller(s) execute a GUI to simultaneously present, on the display device, representations of: the field of view; the zone within the field of view; the position of the surgical object relative to the zone; and a current angle difference between the surgical object and the machine vision camera.

Abstract: A tool for use with a surgical robotic manipulator that comprises an energy applicator including a shaft extending along an axis between a proximal end and a distal end. The shaft has an axial-force receiving surface. A tool assembly comprises a support structure to support the energy applicator, an axial connector assembly arranged to engage and releasably lock the energy applicator to the support structure in a locked state, a drive system coupled to the support structure to rotatably drive the shaft of the energy applicator about the axis, a collet assembly cooperating with the axial connector assembly and configured to apply a force to the axial-force receiving surface of the energy applicator in the locked state, and a reference surface. The force includes an axial component directing the energy applicator proximally into continuous contact with the reference surface in the locked state.

Abstract: A surgical apparatus includes a surgical device and a surgical controller. The surgical device is configured to be manipulated by a user to perform a soft tissue cutting procedure on a patient. The surgical controller is programmed to create a virtual object representing an anatomy of the patient based upon data acquired during a pre-operative scan and associate the virtual object with the anatomy of the patient. The surgical controller is also programmed to identify a plurality of soft tissue attachment points on the virtual object which correspond to a plurality of soft tissue attachment points on the anatomy of the patient. The surgical controller is also programmed to determine the location of the surgical device in relation to the anatomy of the patient and provide real-time visualization on the virtual object of the location of the surgical device in relation to the anatomy of the patient.

Abstract: Robotic surgical systems and methods for resection of an anatomy. The system includes a cutting tool, a manipulator configured to move the cutting tool, and a control system. The control system associates a target plane with the anatomy, the target plane delineating a portion of the anatomy to be resected from a portion of the anatomy to remain unresected. The control system controls the manipulator to align the cutting tool to the target plane. The control system controls the manipulator in an automated mode to perform at least one of the following actions: automatically resect along the target plane with the cutting tool, automatically retract the cutting tool along the target plane, and automatically change a pose of the cutting tool on the target plane. The user or control system can pre-assign whether to perform any of the actions in the manual or automated mode.

Abstract: A method includes providing a boundary defining a portion of a bone to be resected, determining a position of a tracked probe, obtaining a customized boundary by changing a shape of the boundary based on the position of the tracked probe, and guiding operation of a cutting tool in an area defined by the customized boundary.

Abstract: A surgical system and method involve a manipulator including a plurality of links and joints and a tool coupled to the manipulator. A navigation system includes a localizer, a first tracker coupled to the robotic manipulator or the tool, and a second tracker coupled to a workpiece. Controller(s) determine, from the navigation system, a pose of the tool relative to the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a first portion from the workpiece with the tool and sense interaction between the tool and the workpiece during removal of the first portion to detect a density of the workpiece. The controller(s) control the robotic manipulator to facilitate removal of a second portion from the workpiece with the tool, wherein a cutting depth for the second portion is based, at least in part, on the detected density.

Abstract: Surgical systems, methods and surgical planning programs to facilitate preparation of an anatomical cavity to receive a cup implant. The system includes a control system, a localizer and a robotic manipulator configured to move an energy applicator that is adapted to remove tissue. The control system obtains or generates a surgical plan that defines characteristics of cement holes to be formed within a wall of the anatomical cavity for receiving bone cement. The control system registers the surgical plan to the anatomical cavity with the localizer and controls the robotic manipulator to utilize the energy applicator to form the cement holes within the wall of the anatomical cavity according to the surgical plan.

Abstract: A head-mounted device (HMD) and method for assisting a user during a surgical procedure. The HMD has a camera and display supported by a head-mountable structure. The display is positionable in front of eyes of the user. A controller accesses workflow data defining workflow steps associated with the surgical procedure. The controller obtains data from the camera related to an environment of the surgical procedure. The camera data is monitored to detect a deviation or a potential deviation from one or more of the workflow steps. The controller generates an instruction/recommendation to assist the user in taking action to address the deviation or the potential deviation. The instruction/recommendation is specifically tailored to workflow responsibilities of the user. A computer-generated image related to the instruction or the recommendation is provided on the display.

Abstract: A surgical system and method of operating the same. A manipulator supports and facilitates movement of a surgical tool along a tool path relative to a surgical site. A navigation system includes a localizer to monitor states of the manipulator and the surgical site. Controller(s) determine a commanded state of the surgical tool and an actual state of the surgical tool relative to the tool path for a given time step. The controller(s) detect a deviation between the commanded state and the actual state of the surgical tool for the given time step. The controller(s) respond to the deviation by modification of one or both of: a feed rate of the surgical tool; and the tool path. In some implementations, the controller(s) predict, based on the deviation, a future deviation between a future commanded state and a future actual state of the surgical tool for a given future time step.

Abstract: A system for intra-operatively registering a pelvis comprising an acetabulum with a computer model of the pelvis in a coordinate system. The system may include: a) a surgical navigation system including a tracking device; and b) at least one computing device in communication with the surgical navigation system. The at least one computing device: i) receiving first data points from first intra-operatively collected points on an articular surface of the acetabulum, the first data points collected with the tracking device; ii) receiving a second data point from a second intra-operatively collected point on the pelvis, the second data point collected with the tracking device, the second data point corresponding in location to a second virtual data point on the computer model; and iii) determining an intra-operative center of rotation of the femur relative to the pelvis from the first data points.

Abstract: A system for surgical registration. The system may include at least one computing device in communication with a surgical navigation system and the surgical device. The at least one computing device: a) receiving external bone registration data corresponding to locations on the exterior surface of the femur; b) calculating a first registration transform based on the external bone registration data; c) transforming a first bone removal plan of a surgical plan to the operative coordinate system based on the first registration transform; d) receiving internal bone canal registration data corresponding to at least one of location or orientation data from the inner canal of the femur; e) calculating a second registration transform based on both of the external and internal bone canal bone registration data; and f) transforming a second bone removal plan of the surgical plan to the operative coordinate system based on the second registration transform.

Abstract: A surgical system and method involve a robotic system with a base and a localizer that monitors a tracker supported by the robotic system. Sensor(s) are coupled to the robotic system and/or the localizer. Controller(s) determine a relationship between the base and the localizer. The controller(s) monitor the relationship to detect an error related to one or both of the robotic system and the localizer. The controller(s) utilize the sensor(s) to determine a cause of the error.

Abstract: A surgical guidance system for use with a robotic device configured to support and move a surgical tool includes a tracking system configured to track the surgical tool and at least one bone, a display device, and a control system coupled to the tracking system and the display device. The control system is configured to register a plurality of target trajectories to the at least one bone, determine a distance between the surgical tool and each target trajectory, automatically identify which one of the target trajectories is closest to and within a threshold distance of the surgical tool, and display, on the display device, the identified target trajectory relative to the at least one bone and a tracked pose of the surgical tool relative to the identified target trajectory.

Abstract: Surgical systems and methods involve a tracker having at least one trackable component and a localizer configured to track states of the at least one trackable component. An illumination assembly is located remote from the tracker and is operable to direct a visible light. A controller is coupled to the localizer and to the illumination assembly. The controller is configured to detect a condition and control the illumination assembly to remotely direct the visible light at the tracker such that the visible light is reflected by the tracker to communicate the detected condition.

Abstract: A robotic system for preparing a bone to repair a bone fracture, includes a controllable guide structure configured to guide preparation of at least one bone piece during execution of a surgical plan and a control system configured to define the surgical plan. Defining the surgical plan includes determining a desired relationship between at least a first bone piece and a second bone piece that are separated by the bone fracture and planning preparation of the first bone piece to include a prepared anatomical structure configured to align the first bone piece with the second bone piece such that when aligned, the first bone piece and the second bone piece will achieve the desired relationship. The control system is further configured to control the controllable guide structure according to the surgical plan.