Fabrication of implantable bone fixation elements

Claim 1

A method for shaping an implantable rigid bone fixation element comprising: (a) inserting into at least two bone parts at least one securing means for the element, each means engageable with the bone and the element and defining a shape for the element after installation in the bone; (b) aligning the bone to be fixed in the desired configuration; (c) seating a flexible housing having an exterior contour essentially the same as the element engaging in the securing means; (d) injecting fluid molding material into the housing; (e) curing the molding material for a time under conditions sufficient to harden the material so that the housing forms a rigid temporary master having a shape which replicates the shape of the element; and (f) removing the temporary master and using it as a template to form the element.

Claim 2

A method for shaping an implantable rigid bone fixation element comprising: (a) inserting into at least two bone parts at least one securing means for the element, each means engageable with the bone and the element and defining a shape for the element after installation in the bone; (b) aligning the bone to be fixed in the desired configuration; (c) seating a flexible housing having an exterior contour essentially the same as the element engaging in the securing means; (d) injecting fluid molding material into the housing; (e) curing the molding material for a time under conditions sufficient to harden the material so that the housing forms a rigid temporary master having a shape which replicates the shape of the element; and (f) removing the temporary master and using it as a template to form the element.

Claim 8

A method for shaping an implantable rigid spinal column support bar comprising: (a) inserting screws or screw clamps in the vertebrae in the portion of the spinal column to be supported by the bar, wherein the screws or screw clamps have screw members that engage and secure the bar, (b) aligning the column in the desired position; (c) seating flexible hollow tubing in the screw members to simulate the final position of the bar, said tubing having a diameter essentially the same as the bar, (d) injecting a quick-setting fluid molding material into the tubing, (d) curing the molding material for a time under conditions sufficient to harden the molding material in the tubing, and (e) removing the tubing containing the cured molding material and using it as a template for the formation of the bar.

Claim 9

A method for shaping an implantable rigid spinal column support bar comprising: (a) inserting screws or screw clamps in the vertebrae in the portion of the spinal column to be supported by the bar, wherein the screws or screw clamps have screw members that engage and secure the bar, (b) aligning the column in the desired position; (c) seating flexible hollow tubing in the screw members to simulate the final position of the bar, said tubing having a diameter essentially the same as the bar, (d) injecting a quick-setting fluid molding material into the tubing, (d) curing the molding material for a time under conditions sufficient to harden the molding material in the tubing, and (e) removing the tubing containing the cured molding material and using it as a template for the formation of the bar.

Claim 13

A method for shaping an implantable rigid spinal column support bar for maintaining selected predetermined adjacent vertebrae in a predetermined orientation to inhibit front-to-back, side-to-side, and rotational movements of the supported portion of the spinal column comprising: (a) inserting a plurality of pedicle screws in the vertebrae in the portion of the spinal column to be supported by the bar, wherein the screws have screw heads that are proportioned to engage and secure the bar; (b) aligning the vertebrae in the desired configuration to be supported; (c) seating flexible hollow tubing in the screw heads to simulate the final position and shape of the bar, said tubing having a diameter essentially the same as the bar; (d) injecting a quick-setting fluid molding material into the tubing; (e) curing the tubing and molding material for a time under conditions sufficient to harden the material in the tubing, so that the tubing forms a temporary master which follows the position of the screw heads and replicates the bar, and can be used as a template to form a rigid rod sized to fit the determined shape; and (e) removing the temporary master and using it as a template for the formation of the rod.

Claim 14

A method for shaping an implantable rigid spinal column support bar for maintaining selected predetermined adjacent vertebrae in a predetermined orientation to inhibit front-to-back, side-to-side, and rotational movements of the supported portion of the spinal column comprising: (a) inserting a plurality of pedicle screws in the vertebrae in the portion of the spinal column to be supported by the bar, wherein the screws have screw heads that are proportioned to engage and secure the bar; (b) aligning the vertebrae in the desired configuration to be supported; (c) seating flexible hollow tubing in the screw heads to simulate the final position and shape of the bar, said tubing having a diameter essentially the same as the bar; (d) injecting a quick-setting fluid molding material into the tubing; (e) curing the tubing and molding material for a time under conditions sufficient to harden the material in the tubing, so that the tubing forms a temporary master which follows the position of the screw heads and replicates the bar, and can be used as a template to form a rigid rod sized to fit the determined shape; and (e) removing the temporary master and using it as a template for the formation of the rod.