Abstract: Systems and methods are provided for designing and producing custom-made templates for implantation or for pre-contouring metallic or polymer implantable plates prior to surgery. According to one embodiment, medical image data representing surrounding portions of a patient's anatomy to be repaired by surgical implantation of a bone reconstruction plate is received. Next, three-dimensional surface reconstruction is preformed based on the medical image data. Virtual removal of a bone or portion thereof to be reconstructed is performed with reference to the medical image data by simulating the contemplated surgical implantation procedure. Then, a representation of a template is created that is countered to fit the patient's anatomy to be repaired. Finally, a replica of the template is produced by using Solid Freeform Fabrication manufacturing techniques.

Abstract: Systems and methods are provided for designing and producing a custom-fit prosthesis. According to one embodiment, a mold is produced from which a custom-fit implant may be directly or indirectly manufactured. Medical image data representing surrounding portions of a patient's anatomy to be repaired by surgical implantation of the custom-fit implant are received. Then, three-dimensional surface reconstruction is performed based on the medical image data. Next, the custom-fit implant is designed based on the three-dimensional surface reconstruction and a positive or negative representation of a two-part mold is created with a void in the shape of the custom-fit implant by subtracting a representation of the custom-fit implant from a representation of a mold. Finally, the two-part mold is output from which the custom-fit implant may be directly manufactured; or an implant is directly output. Alternatively, an intermediate mold is created from which a two-part mold may be directly manufactured.

Abstract: Systems and methods are provided for designing and producing custom-fit prosthesis. According to one embodiment, a mold is produced from which a custom-fit implant may be directly manufactured. Medical image data representing surrounding portions of a patient's anatomy to be repaired by surgical implantation of the custom-fit implant are received. Then, three-dimensional surface reconstruction is performed based on the medical image data. Next, the custom-fit implant is designed based on the three-dimensional surface reconstruction and a two-part mold is created with a void in the shape of the custom-fit implant by subtracting a representation of the custom-fit implant from a representation of a mold. Finally, the two-part mold is output from which the custom-fit implant may be directly manufactured.