Abstract: A system and process is provided for dynamically positioning or repositioning a robot in a surgical context based on workspace and task requirements, manipulator requirements, or user preferences to execute a surgical plan. The system and method accurately determines and indicates an optimal position for a robot with respect to a patient's anatomy before or during a surgical procedure. Optimal positions for a robot are intuitively indicated to a user. surgical procedures can illustratively include surgery to the knee joint, hip joint, spine, shoulder joint, elbow joint, ankle joint, jaw, a tumor site, joints of the hand or foot, and other appropriate surgical sites.

Abstract: A system and method for intra-operatively measuring or verifying the placement of an implant within a bone in joint arthroplasty procedures are described herein. Pre-operative bone data of the patient is collected. A user plans the position of one or more implants relative to the pre-operative bone data. Intra-operatively, the patients bone is registered to the pre-operative bone data and to a computer-assist device. The bone is prepared and a physical implant is installed with the bone. A plurality of points are digitized on at least one of the physical implant or an apparatus associated with the physical implant. The computer-assist device calculates any errors between the planned position and orientation (POSE) of the implant relative to the actual POSE of the physical implant using the digitized points. The system may further notify a user of any errors and provide instructions to minimize the errors.

Abstract: A system for determining an orientation of a tool axis with respect to a coordinate frame of a robot is described herein. The robot includes a tool holder and a plurality of fiducial markers for defining a first coordinate frame of the robot. A calibration device is provided having a second fiducial marker for a tracking system to track positions and configured to couple to the tool holder; and rotate relative to the tool holder when coupled to the tool holder. A computer having a processor is configured to fit a circle or arc to recorded positions of the calibration device. The recorded positions of the calibration device are recorded when coupled to the tool holder, is rotated relative to the tool holder. A vector normal to the fitted circle or arc is calculated to determine an orientation of the tool axis. A method of use is also provided.

Abstract: A calibration device is provided having a body with an exterior surface configured for placement about a tool such that the body rotates about a tool axis. One or more fiducial marker is positioned on the exterior surface and in communication with a tracking system. A fixed fiducial marker array is provided that is also in communication with the tracking system. A calibration tool defines the tool axis relative to the fiducial marker array. A surgical system is also provided with a tracking module that calculates a center point of the rotation or a normal vector to the circular path to define a tool axis orientation. A method of using the surgical system and defining a tool axis relative to a fiducial marker array is provided. A system for defining a robot link orientation or tracking a tool a medical procedure and a fiducial marker array are provided.

Abstract: A protective drape for a robotic arm is provided. The protective drape may be used with robotic arm that are required to operate in varied environments that illustratively include industrial applications, a sterile surgical suite for patient care, and a clean room for manufacturing sensitive electronic components. In each of these applications, there is a need to prevent contaminants from infiltrating from the environment to the robot and affecting operation of the robot itself or the robotic system, as well to prevent contaminants from the robot from infecting a patient or contaminating an assembly or process product.

Abstract: A method for re-registration between a robotic coordinate system and an image data set is provided. The inventive re-registration method includes the steps of providing an image data set that has been registered within a robotic coordinate system based on an initial bone position; locating a first conserved point and a line segment that is fixed relative to the initial bone position prior to any detectable change in bone position from the initial bone position; relocating the first conserved point and at least a portion of the line segment after bone motion may have occurred to determine the locational change in the first conserved point and the line segment; and re-registering the image data set within the robotic coordinate system based on the determined locational changes. A system for performing this method is also provided.

Abstract: A system and process is provided for dynamically positioning or repositioning a robot in a surgical context based on workspace and task requirements, manipulator requirements, or user preferences to execute a surgical plan. The system and method accurately determines and indicates an optimal position for a robot with respect to a patient's anatomy before or during a surgical procedure. Optimal positions for a robot are intuitively indicated to a user. surgical procedures can illustratively include surgery to the knee joint, hip joint, spine, shoulder joint, elbow joint, ankle joint, jaw, a tumor site, joints of the hand or foot, and other appropriate surgical sites.

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: A system and process is provided for dynamically positioning or repositioning a robot in a surgical context based on workspace and task requirements, manipulator requirements, or user preferences to execute a surgical plan. The system and method accurately determines and indicates an optimal position for a robot with respect to a patient's anatomy before or during a surgical procedure. Optimal positions for a robot are intuitively indicated to a user, surgical procedures can illustratively include surgery to the knee joint, hip joint, spine, shoulder joint, elbow joint, ankle joint, jaw, a tumor site, joints of the hand or foot, and other appropriate surgical sites.

Abstract: A calibration device is provided having a body with an exterior surface configured for placement about a tool such that the body rotates about a tool axis. One or more fiducial marker is positioned on the exterior surface and in communication with a tracking system. A fixed fiducial marker array is provided that is also in communication with the tracking system. A calibration tool defines the tool axis relative to the fiducial marker array. A surgical system is also provided with a tracking module that calculates a center point of the rotation or a normal vector to the circular path to define a tool axis orientation. A method of using the surgical system and defining a tool axis relative to a fiducial marker array is provided. A system for defining a robot link orientation or tracking a tool a medical procedure and a fiducial marker array are provided.

Abstract: A calibration device is provided having a body with an exterior surface configured for placement about a tool such that the body rotates about a tool axis. One or more fiducial marker is positioned on the exterior surface and in communication with a tracking system. A fixed fiducial marker array is provided that is also in communication with the tracking system. A calibration tool defines the tool axis relative to the fiducial marker array. A surgical system is also provided with a tracking module that calculates a center point of the rotation or a normal vector to the circular path to define a tool axis orientation. A method of using the surgical system and defining a tool axis relative to a fiducial marker array is provided. A system for defining a robot link orientation or tracking a tool a medical procedure and a fiducial marker array are provided.

Abstract: A system and method for intra-operatively measuring or verifying the placement of an implant within a bone in joint arthroplasty procedures are described herein. Pre-operative bone data of the patient is collected. A user plans the position of one or more implants relative to the pre-operative bone data. Intra-operatively, the patients bone is registered to the pre-operative bone data and to a computer-assist device. The bone is prepared and a physical implant is installed with the bone. A plurality of points are digitized on at least one of the physical implant or an apparatus associated with the physical implant. The computer-assist device calculates any errors between the planned position and orientation (POSE) of the implant relative to the actual POSE of the physical implant using the digitized points. The system may further notify a user of any errors and provide instructions to minimize the errors.

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 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: A system and process is provided for dynamically positioning or repositioning a robot in a surgical context based on workspace and task requirements, manipulator requirements, or user preferences to execute a surgical plan. The system and method accurately determines and indicates an optimal position for a robot with respect to a patient's anatomy before or during a surgical procedure. Optimal positions for a robot are intuitively indicated to a user, surgical procedures can illustratively include surgery to the knee joint, hip joint, spine, shoulder joint, elbow joint, ankle joint, jaw, a tumor site, joints of the hand or foot, and other appropriate surgical sites.

Abstract: A method for re-registration between a robotic coordinate system and an image data set is provided. The inventive re-registration method includes the steps of providing an image data set that has been registered within a robotic coordinate system based on an initial bone position; locating a first conserved point and a line segment that is fixed relative to the initial bone position prior to any detectable change in bone position from the initial bone position; relocating the first conserved point and at least a portion of the line segment after bone motion may have occurred to determine the locational change in the first conserved point and the line segment; and re-registering the image data set within the robotic coordinate system based on the determined locational changes. A system for performing this method is also provided.

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: 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: A protective drape for a robotic system is provided. The protective drape may be used with robotic systems that are required to operate in varied environments that illustratively include industrial applications, a sterile surgical suite for patient care, and a clean room for manufacturing sensitive electronic components. In each of these applications, there is a need to prevent contaminants from infiltrating from the environment to the robot and affecting operation of the robot itself or the robotic system, as well to prevent contaminants from the robot from infecting a patient or contaminating an assembly or process product.

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.