Stereolithographic anatomical modelling process

Surgery – Diagnostic testing – Detecting nuclear – electromagnetic – or ultrasonic radiation

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Details

128922, 128898, 623901, 378901, 395120, A61F 200, G06F 1542

Patent

active

057412154

DESCRIPTION:

BRIEF SUMMARY
FIELD OF INVENTION

THIS INVENTION is concerned primarily, but not exclusively, with methods and apparatus for forming implantable prostheses and method for use thereof.


BACKGROUND ART

A variety of methods and apparatus for three dimensional modelling of articles including prosthetic implants are known. Many of these techniques employ digitised information from CAD-CAM design systems or data captured and/or reconstructed from a variety of reflection and/or transmission scanning devices.
Such scanning devices include laser and acoustic reflection apparatus and various types of transmission apparatus including X-ray, magnetic resonance imaging (MRI), magnetic resonance angiography (MRA), positron emission (PET) as well as ultrasonic radiation. Typically, data is captured by scanning a series of spaced parallel planes which may then be combined by computer tomography (CT) techniques to reconstruct a two or three dimensional projection of the article so scanned.
Modelling of anatomical pathology using computed tomography data is well known for pre-operative planning and rehearsal of procedures and in the manufacture of prosthetic devices.
U.S. Pat. No. 4436684 describes a non invasive method for forming prostheses of skeletal structures for use in reconstructive surgery. Three dimensional coordinate data is obtained directly from the digital data generated by the computed tomographic information. The three dimensional coordinate data is then utilised to generate three dimensional cylindrical coordinates which are specified relative to an origin which is coincident with the origin of a coordinate system used in a sculpting tool apparatus to specify the spatial location of a cutting tool relative to a workpiece rotating on a turntable.
Due to difficulties in supporting the workpiece however it is generally not possible to sculpt an entire three dimensional model of an article, rather, this system is employed to construct models of portions of skeletal structures to act as male or female mould surfaces for construction of prosthetic inlays or onlays.
This apparatus and system however cannot construct a hollow model having faithfully reproduced external and internal surfaces and structural features.
U.S. Pat. No. 4976737 describes a method of forming a prosthetic device by employing the apparatus and method described in U.S. Pat. No. 4436684 to form a template which may be used directly or indirectly to create a mould surface for moulding a polyurethane impregnated Dacron (Trade Mark) prosthesis. This document describes in detail a "mirror imaging" technique to generate digital data for reconstruction of a missing, damaged or deformed portion of a skeletal structure by transferring image data from one side of an axis of symmetry to another.
Stereolithographic modelling of engineering components from UV sensitive cross-linkable acrylic polymers using CAD/CAM digital data is known. Of more recent times, the use of stereolithography for creation of three dimensional models of bony structures has been reported.
Stereolithographic modelling of anatomical pathology to provide a far more accurate means for physicians and surgeons to examine the condition of a patient for the purposes of diagnosis and for surgical procedures. Rather than rely upon say a solid model representing external features alone (as with U.S. Pat. No. 4436684), with or without two dimensional tomographic images, stereolithographically reproduced representations of anatomical pathology provide an almost exact replica of both internal and external features of a region under consideration.
Moreover, such stereolithographically reproduced models permit surgical procedures to be pre-planned and rehearsed with a great deal of precision to minimise risks and trauma and should enable a means for preparing accurate prostheses for surgical repair of defects or in reconstructive surgery.
One of the difficulties in reconstructing three dimensional co-ordinate data from X-ray tomographic scans is that in order to minimise the amount of radiation to which a pa

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