Abstract: A biocompatible surgical article is provided for cutting biological tissue or implantation in contact therewith. The surgical article has a composition of tungsten carbide—nickel with a percentage of additional metal carbides present. A typical composition in total weight percentages is WC 85 to 95%, Cr3C2, Mo2C, VC each alone or in combination being present from 0 to 2%, and Ni constituting the remainder. The composition is formed to have an mean grain size of between 200 and 800 nm with a particle dispersion index (PdI) corresponding to (the square of the standard deviation)/(mean grain size) of between 0 and 0.6, and in some embodiments between 0.02 and 0.2.

Abstract: Systems and methods for creating cuts on a bone are provided utilizing one or more cutting guides assembled to a plurality of bone pins, where the bone pins are inserted on the bone coincident with one or more virtual pin planes defined relative to one or more of the cuts. Alignment guides are also disclosed herein that aid in the creation of pilot holes for receiving a cutting block in a desired position and orientation (POSE). An articulating surgical device actively positions the bone pins coincident with the virtual plane to ensure the cutting guides, when assembled to the pins, aligns one or more guide slots in the desired POSE to create the cuts.

Abstract: An optical tracking system includes at least one tracking array for generating and optically transmitting data between 1 and 2,000 MB/s. At least one tracker for optically receiving the optically transmitted data between 1 and 2,000 MB/s is also provided. The tracking system is used not only for tracking objects and sending tracking information quickly but also providing the user or other components in an operating room with additional data relevant to an external device such as a computer assisted device. Orthopedic surgical procedures such as total knee arthroplasty (TKA) are performed more efficiently and with better result with the optical tracking system.

Abstract: A system and method are provided that supplies computer inputs using a tracked pointer as an input device during computer-assisted surgery. The system and method provides input or feedback to a computer-assisted surgical device. The system and method utilizes a tracking system for tracking one or more devices in an operating room. The devices include a tracked pointer to input data into a computing system using the anatomy as a reference for selecting an input. The tracked pointer inputs data into the computing system based on the position of the tracked pointer relative to a selection location defined with respect to the anatomy.

Abstract: Systems and methods for creating cuts on a bone are provided utilizing one or more cutting guides assembled to a plurality of bone pins, where the bone pins are inserted on the bone coincident with one or more virtual pin planes defined relative to one or more of the cuts. Alignment guides are also disclosed herein that aid in the creation of pilot holes for receiving a cutting block in a desired position and orientation (POSE). An articulating surgical device actively positions the bone pins coincident with the virtual plane to ensure the cutting guides, when assembled to the pins, aligns one or more guide slots in the desired POSE to create the cuts.

Abstract: A biocompatible surgical article is provided for cutting biological tissue or implantation in contact therewith. The surgical article has a composition of tungsten carbide-nickel with a percentage of additional metal carbides present. A typical composition in total weight percentages is WC 85 to 95%, Cr3C2, Mo2C, VC each alone or in combination being present from 0 to 2%, and Ni constituting the remainder. The composition is formed to have a mean grain size of between 200 and 800 nm with a particle dispersion index (PdI) corresponding to (the square of the standard deviation)/(mean grain size) of between 0 and 0.6, and in some embodiments between 0.02 and 0.2.

Abstract: A method to assist in forming one or more cut surfaces on a bone in preparation for contact with one or more contact surfaces of an implant is provided. Cutting instructions are provided to direct a computer-assisted surgical (CAS) device during formation of a first number of cut surfaces on the bone. The first number of cut surfaces being less than a total number of contact surfaces of the implant. A system for the practice of the method is also provided.

Abstract: A surgical device is provided includes a hand-held portion with a working portion movably coupled to the hand-held portion for driving a tool. Actuators are provided for moving the working portion with each of the actuators having a travel range. An indicator notices a user when at least one of actuators is: (i) within the travel range; (ii) approaching a travel limit of the travel range; or (iii) outside the travel range. A surgical system is also provided inclusive the surgical device and a computing system configured to activate the indicator.

Abstract: A system and method are described herein for determining if hardware installed in a bone is at least partially within a volume of bone to be removed. The method includes determining a location for the volume of bone to be removed relative to a position of the bone. A POSE of a piece of hardware installed in the bone is determined. A computer comprising a processor then calculates if any portion of the piece of hardware is located at least partially within the volume of bone to be removed using the determined location of the volume of bone to be removed and the determined POSE of the piece of hardware. A user may be notified if any portion of the hardware is located at least partially within the cut volume.

Abstract: A method to guide in preparation of a bone relies on an instrument having a shaft with a working end and a stop member. The shaft is free to translate along an axis. Surgical planning data is registered to the bone to determine intra-operative coordinates of the desired axis and depth. The instrument holder is positioned by the bone so the stop member contacts the instrument holder to prevent translating beyond the desired depth. Alternatively, an arm is manipulated to align the instrument with the desired axis. The working end rests on the bone to define a linear separation to the desired depth. By proximally translating the instrument holder to contact the stop member and distally translating the instrument holder along the shaft, the stop member physically stops translating beyond the desired depth. A surgical system for performing the methods is provided; a reamer or impactor are also disclosed.

Abstract: Systems and methods are provided to aid in planning at least a portion of a total knee arthroplasty procedure. The system and method automatically aligns the implant components and the bones according to a desired clinical alignment goal with minimum user input. The system and method further allows the user to adjust the position and orientation of the femur, tibia, or implant in a clinical direction regardless of a pre-adjusted position and orientation of the femur, tibia, or implant. The graphical user interface is provided that includes a three-dimensional (3-D) view window, a view options window, a patient information window, an implant family window, a workflow-specific tasks window, and a limb and knee alignment measures window.

Abstract: Systems and methods for creating cuts on a bone are provided utilizing one or more cutting guides assembled to a plurality of bone pins, where the bone pins are inserted on the bone coincident with one or more virtual pin planes defined relative to one or more of the cuts. Alignment guides are also disclosed herein that aid in the creation of pilot holes for receiving a cutting block in a desired position and orientation (POSE). An articulating surgical device actively positions the bone pins coincident with the virtual plane to ensure the cutting guides, when assembled to the pins, aligns one or more guide slots in the desired POSE to create the cuts.

Abstract: A computer-assisted method is provided for determining a placement position for an implant relative to a bone. According to the method, a force profile exerted on a bone is calculated from bone density data and bone architecture data. A position and orientation (POSE) for an implant in relation to the bone based is then determined, at least in part, on the calculated force profile. A computing system is provided that includes a computer having a processor and non-transient memory programmed with operating planning software that when executed by the processor is configured to: calculate a force profile exerted on a bone from bone density data and bone architecture data and determine a position and orientation (POSE) for an implant in relation to the bone based, at least in part, on the calculated force profile.

Abstract: A system and method are described herein for installing hardware in a bone outside an end-effector's tool path prior to modifying the bone. The method includes the installation of a first piece of hardware in the bone. The bone and a cut volume to be created in the bone is registered to a computer-assist device. A processor calculates whether the hardware is within the cut volume based on the geometry and POSE of the hardware relative to the POSE of the cut volume. A user is notified if the hardware is at or inside the cut volume based on the calculation. If so, a second piece of hardware is installed in the bone and the calculation is repeated to determine if the second piece of hardware is at or inside the cut volume. The surgical procedure may commence when an installed piece of hardware is installed outside the cut volume.

Abstract: A system is provided that includes a surgical robot having an end-effector and a plurality of actuators for moving the end-effector. The end-effector movement being in response to first control signal to align the end-effector with a first virtual plane having a first predefined location relative to a first portion of a bone or bone fragments for performing a first operation thereon. A second control signal aligns the end-effector with a second virtual plane having a second predefined location relative to a second portion of the bone or bone fragments for performing a second operation thereon. A feedback mechanism can also be provided based on relative locations. A method for repairing a defect in a bone is provided based on the operation of an inventive system to move the end-effector. Bone modification results to correct a defect in the bone.

Abstract: A method of detecting a potential collision between an end-effector and bystander anatomy is provided. A cut-file or a representation of an implant is registered to a position of a first bone, the registered cut-file defining at least one orientation for an end-effector axis to assume while physically modifying the first bone. Imaging data of bystander anatomy is registered to a position of the bystander anatomy. The at least one orientation of the end-effector axis as defined in the registered cut-file is calculated in a computer if it has a spatial overlap with the registered imaging data to detect the potential collision. A portion of the registered representation can also projected along an axis with the projection used to determine possible collisions and if so provide the user with options.

Abstract: A method for registering one or more surfaces associated with a bone for implant revision procedures includes a digitizer used to digitize surface points on remaining cement, bone surfaces, or both. The bone is adapted to hold a primary implant and from which the primary implant was removed. The position of the one or more surfaces associated with bone is registered by computing at least one of: a generic set of one or more planes using the surface points or a best match between a known implant geometry and the surface points. A computer-assisted surgical system is also provided to execute the method.

Abstract: A method and system are provided to determine an optimal placement with respect to position and orientation for one or more bones in a workspace of a robot to improve robotic cutting and maximize the robot workspace during a robotic surgical procedure. The method is additionally useful to aid a user in positioning and orienting the bones in the operating room at the determined position and orientation.

Abstract: A magnetic impactor assembly is described herein. The magnetic impactor assembly generally includes a guide receptacle, and an impactor guide magnetically coupled to the guide receptacle to form a magnetic interface therebetween. The guide receptacle is attachable to a surgical device such as a surgical robotic manipulator arm. The impactor guide receives and guides an impactor to permit a user to impact a prosthesis into a bone of a patient in a planned position and orientation. The magnetic impactor assembly reduces the transmission of excessive forces to a patient or the surgical device if an off-axis impaction force is generated on the impactor through the decoupling of the impactor guide from the guide receptacle.

Abstract: A system, device, and method is provided that improves the point collection process during bone registration for computer-assisted surgical procedures. A user is guided in the point collection process by projecting a set of points directly on the bone with a tracked digitizer probe following a rough registration of the bone. The system, device, and method therefore negates the need for the user to constantly look-up on an instructional display monitor and make the complicated mappings between the displayed instructions on the monitor and the actual bone.