Abstract: An orthopedic implant manufacturing method. The method includes preparing a pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient's joint indicating at least one resection plane, communicating the surgical plan to a surgeon of the patient, and receiving approval of the surgical plan and the resection plane by the surgeon. The method also includes providing automated osteophyte/protrusion removal control for surgeon manipulation, receiving a modified three-dimensional image of a patient's joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from the surgeon, and requesting manufacture of the selected orthopedic implant.

Abstract: An orthopedic device includes a femoral implant having a non-custom internal bone engagement surface. The femoral implant includes at least nine parameters adjusted preoperatively to correspond to a specific patient. The parameters can include patient-specific lengths, such as, for example, medial and lateral condyle widths and notch height, and patient-specific medial and lateral angles.

Abstract: A patient-specific unicompartmental tibial guide has a patient-specific body with an inner surface. The inner surface is preoperatively configured to nestingly conform and mate in only one position with an anterior portion and a proximal portion of a tibial bone of a specific patient. The tibial guide includes a vertical resection channel having a variable width preoperatively configured for guiding a vertical resection through the proximal portion of the tibial bone.

Abstract: An orthopedic device includes a drill guide configured to be mounted on a patient-specific alignment guide for intraoperatively confirming alignment of the patient-specific alignment guide relative to a bone. The patient-specific alignment guide includes first and second referencing holes. The drill guide includes a main body with a first coupling member and a second coupling member. The first and second coupling members are configured to be received within the first and second referencing holes, respectively. The first and second coupling members each include corresponding first and second drill openings configured to align with the first and second referencing holes, respectively. The drill openings each guide a drilling tool toward the bone to drill corresponding holes in the bone. The main body also includes an alignment confirmation feature configured for confirming alignment of the patient-specific alignment guide relative to the bone before drilling holes in the bone.

Abstract: A method for preparing surgical kits for use during a surgery includes preparing a pre-operative surgical plan for a patient and selecting a set of surgical instruments based on the pre-operative surgical plan. The set of surgical instruments includes at least a general instrument, a first size-specific instrument, a patient-specific instrument, and a surgeon-specific instrument. The general instrument is selected from a predetermined group of off-the-shelf instruments. The first size-specific instrument has a first size selected from predetermined sizes. The patient-specific instrument includes a three-dimensional contoured engagement surface configured to nest into a portion of a native anatomy in a single location. The surgeon-specific instrument is selected based on a surgeon preference and is a different instrument than the selected general instrument, first size-specific instrument, and patient-specific instrument.

Abstract: A convertible patient-specific guide for use in arthroplasty has a body having a patient-specific three-dimensional undersurface closely mateable engageable in only one position with a corresponding joint surface of a specific patient. The convertible guide includes patient-specific guiding formations extending from the body and configured for guiding both a total arthroplasty of the joint and a partial arthroplasty of the joint, such that the arthroplasty to be performed is intraoperatively changeable.

Abstract: An orthopedic device for joint arthroplasty includes a patient-specific alignment guide constructed and configured for a specific patient from medical scans that show a bone surface of a bone of the patient without any overlying soft tissue. The patient-specific alignment guide includes a patient-specific inner surface configured to be offset from and mimic the bone surface and form a clearance for soft tissue overlying the bone surface. The alignment guide also includes a plurality of patient-specific contact areas configured to mate and register directly on the bone surface without intervening soft tissue for direct bone registration. The plurality of patient-specific contact areas includes non-contiguous surface contact areas.

Abstract: An orthopedic device includes a patient-specific alignment guide operable for preparing a bone of a patient for resection during joint arthroplasty. The alignment guide includes a patient-specific bone engagement surface complementary to a surface of the bone of the patient and imaged from a bone scan of the patient. The alignment guide includes a plurality of guiding bores, and a plurality of alignment pins received through corresponding guiding bores for attaching the alignment guide to the bone. The alignment pins are resorbable and can be cut off during a resection of the bone.

Abstract: An orthopedic device includes a femoral implant having a non-custom internal bone engagement surface. The femoral implant includes at least nine parameters adjusted preoperatively to correspond to a specific patient. The parameters can include patient-specific lengths, such as, for example, medial and lateral condyle widths and notch height, and patient-specific medial and lateral angles.

Abstract: An orthopedic implant manufacturing method. The method includes preparing a pre-operative surgical plan for a specific patient, the surgical plan including a three-dimensional image of a patient's joint indicating at least one resection plane, communicating the surgical plan to a surgeon of the patient, and receiving approval of the surgical plan and the resection plane by the surgeon. The method also includes providing automated osteophyte/protrusion removal control for surgeon manipulation, receiving a modified three-dimensional image of a patient's joint indicating an osteophyte/protrusion removal and a recommendation for a corresponding selected orthopedic implant from the surgeon, and requesting manufacture of the selected orthopedic implant.