Abstract: Systems and processes for designing and generating personalized surgical implants and devices are described herein. In various embodiments, the process includes generating patient-specific implants with patient-specific surface(s) and/or textures designed for increased osseointegration and improved surgical outcomes. In various embodiments, the process includes extracting patient-specific data with one or more aspects of an anatomical feature, processing the one or more aspects of the anatomical feature to create a non-rigid shape reference, and generating a patient-specific implant or device.

Abstract: Provided herein are ligament docking implants and methods for making and using the same. In at least one embodiment, the implants include at least one docking recess configured to receive a tissue structure such as a ligament and connect said tissue to the implant via suitable surgical techniques. In at least one embodiment, the docking recesses of the implant include a gyroid architecture that provides for improved mechanical performance and tissue integration. In various embodiments, the present methods of using the ligament docking implants include the use of sutures to connect tissue to the implant via the docking recess.

Abstract: The present disclosure generally discloses instruments and methods of using those instruments for performing various aspects of ankle replacement surgery. In one embodiment, an alignment assembly for adjusting a position of a guide tool relative to a patient is provided. The alignment assembly includes a proximal housing; a distal housing configured to be connected to the guide tool; and at least one linkage system configured to adjust a relative angle between at least two portions of the alignment assembly. A surgical guide wire is also disclosed. The surgical guide wire includes a distal tip having a tapered or trocar end configured for insertion into a bone; a distal region adjacent to the distal tip; a transition region adjacent to the distal region; and a proximal region adjacent to the transition region.

Abstract: A surgical guide assembly is disclosed herein that includes instruments configured to aid in the alignment of surgical instruments. In one aspect, a first and second instrument are provided that are configured to be connected to each other via interfaces and each define bone contact interface. The bone contact interfaces are configured to engage with the tibia and talus, in one embodiment.

Abstract: Provided herein are 3D-printed patient-specific surgical guides and methods for making and using the same. In at least one embodiment, the guides include a first and second end, a first and second side, a conformal bone engaging surface, a front surface, one or more porous regions, one or more walls, and a plurality of openings. At least one of the plurality of openings extends through the guide between the conformal bone engaging surface and the front surface. The conformal bone engaging surface is contoured to a patient's anatomy. The first and second end, and the first and second side are contoured to avoid soft tissues of the patient.

Abstract: Provided herein are implants and methods for producing implants. In at least one embodiment, the implants include sheet-based, triply periodic, minimal surface (TPMS) portions. According to one embodiment, the TPMS portions include a gyroid architecture that provides for improved osseointegration and mechanical performance over previous implants due to novel ratios of porosity to compressive strength, among other features. In one or more embodiments, the gyroid architecture is organized into unit cells that demonstrate anisotropic mechanical performance along an insertion direction. In various embodiments, the present methods include novel selective laser melting (SLM) techniques for forming the TPMS portions of implants in a manner that reduces defect formation, thereby improving compressive performance and other implant properties.

Abstract: Provided herein are implants and methods for producing implants. In at least one embodiment, the implants include sheet-based, triply periodic, minimal surface (TPMS) portions. According to one embodiment, the TPMS portions include a gyroid architecture that provides for improved osseointegration and mechanical performance over previous implants due to novel ratios of porosity to compressive strength, among other features. In one or more embodiments, the gyroid architecture is organized into unit cells that demonstrate anisotropic mechanical performance along an insertion direction. In various embodiments, the present methods include novel selective laser melting (SLM) techniques for forming the TPMS portions of implants in a manner that reduces defect formation, thereby improving compressive performance and other implant properties.

Abstract: The present disclosure relates generally to custom medical devices and additive manufacturing (3D printing) processes for producing the same. Using certain materials and novel fabrication techniques, the present systems and methods can directly print nearly any size or shape medical device or instrument. For example, in certain embodiments, the present systems and methods leverage stereolithography (“SLA”) and photo-curable polymers to produce custom, radiopaque medical devices and instruments.

Abstract: The present disclosure relates generally to medical devices, including airway stents, and additive manufacturing (3D printing) processes for producing the same. Using certain materials and novel printing techniques, the present systems and methods can directly print nearly any size or shape medical device in a few hours. For example, in certain embodiments, the present systems and methods leverage fused deposition modeling (“FDM”) and polycarbonate urethane (“PCU”) to produce custom medical devices, including airway stents.

Abstract: Provided herein are implants and methods for producing implants. In at least one embodiment, the implants include sheet-based, triply periodic, minimal surface (TPMS) portions. According to one embodiment, the TPMS portions include a gyroid architecture that provides for improved osseointegration and mechanical performance over previous implants due to novel ratios of porosity to compressive strength, among other features. In one or more embodiments, the gyroid architecture is organized into unit cells that demonstrate anisotropic mechanical performance along an insertion direction. In various embodiments, the present methods include novel selective laser melting (SLM) techniques for forming the TPMS portions of implants in a manner that reduces defect formation, thereby improving compressive performance and other implant properties.