Abstract: An orthopedic surgical instrument includes from about 40 wt % to about 85 wt % of a base thermoplastic and from about 15 wt % to about 60 wt % of a filler material. The base thermoplastic includes polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof. In some aspects all materials in the orthopedic surgical instrument are biocompatible. An orthopedic surgical kit includes an orthopedic surgical instrument and a container suitable for sealing the orthopedic surgical instrument therein. The orthopedic surgical instrument in the kit includes from about 50 wt % to about 90 wt % of a base thermoplastic selected from the group consisting of polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof, and from about 10 wt % to about 50 wt % of a filler material.

Abstract: A method for making a customized orthopedic surgical instrument for use in repairing a joint of a patient includes: obtaining image data associated with at least a portion of a bone corresponding to the joint of the patient; generating instructions to form a patient-specific orthopedic surgical instrument based at least in part on the image data; and forming the patient-specific orthopedic surgical instrument based on the instructions. The patient-specific orthopedic surgical instrument includes a resin composition, the resin composition including from about 50 wt % to about 90 wt % of a base thermoplastic and from about 10 wt % to about 50 wt % of a filler material. The base thermoplastic includes polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof. The orthopedic surgical instrument includes at least one surface portion having a shape that substantially conforms to a corresponding surface portion of the bone.

Abstract: A system for making a customized orthopedic surgical instrument for use in repairing a joint of a patient includes a computer system for generating computer-readable instructions to form a patient-specific orthopedic surgical instrument based at least in part on image data obtained from at least a portion of a bone corresponding to the joint of the patient; and a machine for forming a patient-specific orthopedic surgical instrument from the computer-readable instructions. The surgical instrument includes a resin composition including from about 50 wt % to about 90 wt % of a base thermoplastic and from about 10 wt % to about 50 wt % of a filler material. The base thermoplastic includes polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof. The surgical instrument includes at least one surface portion having a shape that substantially conforms to a corresponding surface portion of the bone.

Abstract: An orthopedic surgical instrument includes from about 40 wt % to about 85 wt % of a base thermoplastic and from about 15 wt % to about 60 wt % of a filler material. The base thermoplastic includes polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof. In some aspects all materials in the orthopedic surgical instrument are biocompatible. An orthopedic surgical kit includes an orthopedic surgical instrument and a container suitable for sealing the orthopedic surgical instrument therein. The orthopedic surgical instrument in the kit includes from about 50 wt % to about 90 wt % of a base thermoplastic selected from the group consisting of polyetherimide, polycarbonate, modified polyphenylene ether, polyamide, copolymers of these thermoplastics, and combinations thereof, and from about 10 wt % to about 50 wt % of a filler material.