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 debris clearing system is provided that includes a tool having a suctioning intake positioned on an axis of the tool. A controller actuates the suctioning intake along the length of the axis of the tool. The suctioning intake is actuated while the tool is being operated and proximal to a surgical site on a patient's anatomy. A method of use is also provided for suctioning debris from a surgical field during a procedure.

Abstract: A method and system are provided to intraoperatively adjust the dimensions of a pre-operatively planned implant cavity to improve implant fit in a bone. The method includes obtaining a preoperative image data set of the bone. A surgical plan is generated using the image data set and/or a three-dimensional (3-D) bone model of the patient's bone generated from the image data set. Intraoperatively, the patient's bone is exposed and registered to the surgical plan and a computer assisted surgical system. The computer assisted surgical system having a cutting tip and a force sensor for sensing actual forces exerted on the cutting tip as an initial cut is created on the bone at a first bone region. Based on the difference between the actual cutting force and the expected cutting force in the plan, the dimensions of the cavity are adjusted accordingly.

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: An articulating drill system is provided that includes a hand-held portion and a drill portion. At least two actuators are provided for controlling at least two axes of the drill portion. A navigation system is provided to control the at least two actuators. In some embodiments, a tool is provided with the drill portion and adapted to interact with patient tissue. The drill portion can be modified to include at least two rigid objects in communication with the actuators and attached to the drill portion. The system can be used to make any linear cut within a deviation of 1.0 mm and 1.0?, or better in patient tissue.

Abstract: Systems and processes are provided that utilize the accuracy and adaptability of an optical tracking system to track an object by maintaining a line of sight (LOS) between the optical signals from the tracked object and the optical receivers regardless of the position and orientation of the object being tracked. LOS is maintained without having to manually adjust a tracked device or the optical receivers, or be limited to a specified working volume. Instead, whenever the tracked device moves, an active controller device calculates new values for the degrees of freedom of a series of joints holding a tracking array to the tracked object to position and orient the tracking array to maintain visibility to the optical receivers. A computer-assisted or robotic device that decreases operating times, and improves surgical accuracy, without additional user requirements or adjustments to maintain the LOS of the optical tracking system is provided.

Abstract: Methods, devices and systems for the planning and execution of computer-assisted robotic surgery are provided. The methods include methods to collect information about bones and prostheses, use the information to create virtual models and simulations, optionally receive input based on user discretion in generating the cut file, and to generate instruction for the execution of cut paths during the surgery. The system and devices include computers and peripherals and set-ups to link the components together into functional systems.

Abstract: A process for creating a curved contour on or within a bone is provided, where the process includes positioning a bone of a patient in a fixed position in a coordinate system, generating scan data of the bone, creating a three-dimensional surface model of the bone based on the scan data, generating a cutting program to modify a surface of the bone based on the three-dimensional surface model and a prosthesis having a bone interface shape that is complementary to the curved contour, and modifying the bone with one or more curved blades or a curved drill bit that is robotically driven and positioned with the cutting program to form the curved contour. A system for creating a curved congruent contour on or within a bone for mounting a prosthesis is also described.

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 process and system for performing orthopedic surgery with the use of computer systems and robotic assistance to remove bone, bone cement, and a bone prosthesis, typically a bone prosthesis used in hip replacement surgery, knee replacement surgery, and the like. The process for replacing one or more bone prostheses using a robotic system includes receiving image data comprising an image of each bone, including at least one prosthesis implanted within each bone; creating three-dimensional models of the prosthesis, and the bone; creating a plan for positioning new prostheses within the bone; determining the location and amount of bone and any non-bone material to be removed for the new prostheses; and removing the bone prosthesis from the bone. The inventive process may be used for the replacement of hip joints, shoulder joints, ankle joints, wrist joints, finger joints, toe joints, or other joints.

Abstract: Described herein are methods, systems and devices for image-guided, computer-assisted surgical procedures, in particular for intra-operative registration of anatomical structures. Embodiments of the invention may enable a user to register the surface of an anatomical structure intra-operatively in an interactive, computer-guided process. The user may send information about acquired data points to the computer, and the computer may evaluate the aggregate of data points, optionally provide instructions to the user for acquisition of additional data points, and signal to the user when sufficient data points have been acquired for registration of the surface of the anatomical structure.

Abstract: A contactless, and accurate device and methods of use thereof are provided to calibrate and verify the calibration of a robotic arm and associated attachments. The device uses a laser gauge for calibrating and subsequently verifying the calibration of the robotic arm, digitizer, or robotic tools. An optical transmitter, in communication with an optical receiver is fixed nearly perpendicular to a second optical transmitter in communication with a second optical receiver that form two optical micrometers that are offset a small distance, forming a small gap, d, to create a measuring void having two distinct non-intersecting measurement planes. One measurement plane measures the position and size of an object in a first axis direction and the other measurement plane measures the position and size of an object in a second axis direction. The position and size of an object is measured within the measuring void in both axial directions.

Abstract: A system and process for performing orthopedic surgery is provided that uses a patient's existing implant as a registration tool in an orthopedic surgical procedure. The systems and processes may be used with computer assisted systems or navigation systems to aid in the removal of bone, bone cement, or a bone prosthesis, typically a bone prosthesis used in hip replacement surgery, knee replacement surgery, and the like. The removal of the prosthesis may be done by conventional methods, with navigation systems, robotic assistance or articulating hand held systems. The removal of bone and/or bone cement may be performed with navigated systems, robotic systems, articulating hand-held systems and combinations thereof.

Abstract: Described herein are systems and processes for performing femoroacetabular impingement hip surgery using a robotic system. In general, the processes may include receiving an image of the at least one bone; creating three-dimensional models of the at least one bone; determining the location of the at least one bone such that a precise orientation is known; Using software to automatically generate a volume of the at least one bone to be removed; automatically performing robotically controlled milling to remove the impinging at least one bone; and providing a simulated kinematic analysis of motion of the at least one bone after it is removed. The process may further include the step of receiving input from the user, determined manually by said user, based on the three dimensional-models of the at least one bone, to modify a volume of the at least one bone to be removed.

Abstract: Methods and systems to optimize ligament reconstruction surgical outcomes by enabling bone tunnel(s) to be precisely and optimally placed through the use of pre-operative planning systems coupled with precision control bone evacuation machines, such as robotic drills are provided. The methods generally include receiving and processing scan data of a patient's bone(s); pre-determining the optimal tunnel placement parameter(s) with the scan data; placing registration marker(s) on the patient's bone(s) percutaneously; and creating a tunnel in the patient's bone(s) with a system coupled to receive and execute according to the pre-determined optimal tunnel placement parameter(s).

Abstract: A system and a device are provided for counterbalancing a surgical robotic system that include a rail assembly having a shaft that engages a first carriage and a second carriage via threaded mechanism. A manipulatable arm carries a movable effector; the manipulatable arm is supported by the first carriage. A counter weight is supported by the second carriage with a single actuator. A simplified robotic surgery system results.

Abstract: Described herein are systems and methods for creating a custom registration guide. In general, the methods may include receiving scan data of a patient's bone; creating instructions based on the scan data for creating a three-dimensional surface model of the patient's bone; and moving a plurality of moveable elements, coupled to the adjustable model, based on the instructions. The method may further include the steps of placing a malleable registration guide onto the adjustable model and shaping the registration guide to fit to the adjustable model. The method may further include the step of intraoperatively determining the location of a patient's bone using the custom registration guide. The step of determining the location of the patient's bone may include the steps of coupling the registration guide and fiducial markers to the patient's bone.

Abstract: Systems and methods for monitoring an operative site during a surgical procedure using a computer controlled surgical device. In general the methods include the steps of processing one or more defined cutting paths having one or more cut regions; determining a correlation between the cut region and one or more critical regions to generate an alert, wherein the alert indicates a movable end-effector is within a defined proximity of the critical region; and requiring a user acknowledgment of the alert to allow processing of the cutting path to continue. Also described herein are systems and methods for minimizing user fatigue during a semi-computer controlled surgical procedure. In general the methods includes the step of requiring a user generated acknowledgment in response to a computer generated alert, wherein the user acknowledgment is generated using a user controller, the user controller being minimally intrusive to the user experience.

Abstract: A shape memory actuator system is provided that includes a shape memory actuator having a body made of a shape memory material, with individual power conductors interfaced with a first portion of the body, and one or more individual ground conductors interfaced with a second portion of the body in physical contact with the first portion of the body. A power source provides power to the individual power conductors. A controller is provided for controlling a resistive heating current connection sufficient to impart shape memory to the body between the individual power conductors and the one or more individual ground conductors with the proviso that the ground conductors are physically separated from the individual power conductors. A novel shape memory article results. A method for controlling a shape memory actuator and forming a shape memory article are also provided.

Abstract: A method for implantation of non-spherical, asymmetric implants is provided that includes devising a pre-surgical plan with pre-operative planning software operating on a computer to define at least one of shape, orientation, type, size, geometry, or placement of the non-spherical, asymmetric implant in an operative bone of a subject. A computer assisted surgical device is used to place the non-spherical, asymmetric implant. The implant is positioned within the bone by the computer assisted surgical device in accordance with pre-surgical plan. A non-spherical, asymmetric implant for insertion in a bone formed of separate stem, neck, and head portions and suitable for implantation by the method is also disclosed.