Systems and methods for planning and performing image free implant revision surgery

A system comprising:

• a surgical instrument including a tracking array;
• a tracking system including a tracking sensor, the tracking system monitoring, in real-time, three dimensional position and orientation of the surgical instrument and a previously resected target bone of the implant host;
• a control system, the control system including:
• a communication interface coupled to the tracking system to receive tracking information identifying a current surgical instrument position and a current previously resected target bone position;
• one or more processors coupled to a memory device, the memory device including instructions that, when executed by the one or more processors, cause the control system to perform operations including:
• collecting, from the tracking system based on locations of the surgical instrument associated with the previously resected target bone, pre-defined parameters characterizing the previously resected target bone;
• generating a voxellized three dimensional (3D) cylinder enclosing the portion of the previously resected target bone associated with an implant revision procedure based at least in part on a portion of the pre-defined parameters, wherein the previously resected target bone was resected to accommodate a previously installed prosthetic implant;
• receiving, from the tracking system, a plurality of surface points from a portion of the previously resected target bone associated with the implant revision procedure based on a tracing of the surgical instrument along a surface of the portion of the previously resected target bone associated with the implant revision procedure;
• and
• generating a reshaped voxellized 3D model by performing volume subtraction from the voxellized 3D cylinder based on the plurality of surface points collected from the portion of the previously resected target bone.

A machine-readable storage device including instructions that, when executed by a machine, cause the machine to perform operations including:

• generate, using one or more processors within the machine, a voxellized three dimensional (3D) model to approximate a previously resected target bone based at least in part on a pre-defined set of parameters characterizing the previously resected target bone, wherein the previously resected target bone was resected to accommodate a previously installed prosthetic implant;
• receive, from a tracking system tracking a tracked surgical instrument, a plurality of surface points from a portion of the previously resected target bone associated with an implant revision procedure based on a tracing of the surgical instrument along a surface of the portion of the previously resected target bone associated with the implant revision procedure;
• and
• generate, using the one or more processors, a reshaped voxellized 3D model by performing volume subtraction from the voxellized 3D model based on the plurality of surface points collected from the portion of the previously resected target bone to update voxels within the voxellized 3D model.