# US 2010/0168753 A1 · Orthopaedic cutting block having a chemically etched metal insert and method of manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2010/0168753 A1 - Document ID: US20100168753A1 - Status: Published application - Kind: A1 - Application number: 12/345,118 - Filed: 2008-12-29 - Published: 2010-07-01 - Earliest claimed: 2008-12-29 - Assignees: Depuy (Ireland) - Inventors: Jon M. Edwards; Henri G. Asselin, JR.; Todd R. Beaupre; Donald E. Welling; Roger J. White - Web page: https://patentgrep.com/patent/US20100168753A1 ## CPC - A61B 17/1764: {for the knee} - A61B 17/155: {Cutting femur} - A61B 17/157: {Cutting tibia} - A61B 17/1659: {Surgical rasps, files, planes, or scrapers} - A61B 17/1675: {for the knee} - C23F 1/14: Aqueous compositions - A61B 17/152: {for removing a wedge-shaped piece of bone} - A61B 17/1615: {Drill bits, i.e. rotating tools extending from a handpiece to contact the worked material} - A61B 2017/00526: {Methods of manufacturing} - A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D) - C23F: NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE (working metal by laser beams B23K26/00; desurfacing by applying flames B23K7/00; working of metal by electro-erosion B23H; producing decorative effects by removing surface material, e.g. by engraving, by etching, B44C1/22; electrolytic etching or polishing C25F); INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25 ## Abstract An orthopaedic surgical instrument comprising an orthopaedic cutting block includes a metallic bearing insert configured to support a bone cutting tool and a body molded to the bearing insert. The bearing insert includes a plurality of chemically etched holes, and the body is molded to the bearing insert such that each of the plurality of chemically etched holes is at least partially filled by a portion of the body. The body of the orthopaedic cutting block may include a bone-facing surface adapted to contact a portion of a patient's bone, and the bearing insert may be positioned to allow a surgeon to perform a cut on the patient's bone using the bearing insert for support. A method of manufacturing an orthopaedic surgical instrument is also disclosed. ## Claims ### Claim 1 An orthopaedic cutting block, comprising: a metallic bearing insert having a plurality of chemically etched holes, the bearing insert being configured to support a bone cutting tool; and a body molded to the bearing insert such that each of the plurality of chemically etched holes is at least partially filled by a portion of the body. ### Claim 2 (depends on 1) The orthopaedic cutting block of claim 1, wherein: the bearing insert has (i) an interface surface which contacts the body, and (ii) a guide surface opposite the interface surface, the guide surface configured to support the bone cutting tool; and each of the plurality of chemically etched holes extends from the interface surface to the guide surface of the bearing insert. ### Claim 3 (depends on 2) The orthopaedic cutting block of claim 2, wherein the portion of the body which at least partially fills each chemically etched hole fills at least half the volume of the hole. ### Claim 4 (depends on 2) The orthopaedic cutting block of claim 2, wherein the bearing insert comprises a bushing, the guide surface being configured to support a bone drill bit. ### Claim 5 (depends on 2) The orthopaedic cutting block of claim 2, wherein the bearing insert comprises a non-captured cutting guide, the guide surface being configured to support a bone saw blade. ### Claim 6 (depends on 1) The orthopaedic cutting block of claim 1, wherein: the body includes a bone-facing surface adapted to receive a portion of an anterior side of a patient's tibia; and the bearing insert is positioned to allow a surgeon to perform a proximal cut on the patient's tibia using the bearing insert for support. ### Claim 7 (depends on 1) The orthopaedic cutting block of claim 1, wherein: the body includes a bone-facing surface adapted to receive a portion of an anterior side of a patient's femur; and the bearing insert is positioned to allow a surgeon to perform a distal cut on the patient's femur using the bearing insert for support. ### Claim 8 (depends on 1) The orthopaedic cutting block of claim 1, wherein: the body includes a bone-facing surface adapted to contact a resected distal surface of a patient's femur; and the bearing insert is positioned to allow a surgeon to perform at least one of an anterior cut, a posterior cut, and a chamfer cut on the patient's femur using the bearing insert for support. ### Claim 9 (depends on 1) The orthopaedic cutting block of claim 1, wherein: the body includes a first bone-facing surface adapted to contact a resected anterior surface of a patient's femur and a second bone-facing surface adapted to contact a resected distal surface of the patient's femur; the guide surface of the bearing insert comprises a medially-facing section, a laterally-facing section, and a distally-facing section; and the bearing insert is positioned to allow a surgeon to perform a notch cut on a patient's femur using the bearing insert for support. ### Claim 10 (depends on 1) The orthopaedic cutting block of claim 1, wherein the body comprises an injection-molded polymer. ### Claim 11 An orthopaedic surgical instrument, comprising: an orthopaedic cutting block having (i) a first metallic bearing insert having a first plurality of chemically etched holes, the first bearing insert being configured to support a bone cutting tool, (ii) a second metallic bearing insert having a second plurality of chemically etched holes, the second bearing insert being configured to support the bone cutting tool, and (iii) a body molded to the first and second bearing inserts such that each of first plurality of chemically etched holes and each of the second plurality of chemically etched holes is at least partially filled by a portion of the body. ### Claim 12 (depends on 11) The orthopaedic surgical instrument of claim 11, wherein: the first bearing insert has (i) a first interface surface which contacts the body, and (ii) a first guide surface opposite the first interface surface, the first guide surface configured to support the bone cutting tool; each of the first plurality of chemically etched holes extends from the first interface surface to the second guide surface of the first bearing insert; the second bearing insert has (i) a second interface surface which contacts the body, and (ii) a second guide surface opposite the second interface surface, the second guide surface configured to support the bone cutting tool; and each of the second plurality of chemically etched holes extends from the second interface surface to the second guide surface of the second bearing insert. ### Claim 13 (depends on 11) The orthopaedic surgical instrument of claim 11, wherein the first bearing insert opposes the second bearing insert with a gap therebetween, the first and second bearing insert comprising a captured cutting slot configured to support a bone saw blade. ### Claim 14 A method for manufacturing an orthopaedic surgical instrument, the method comprising: chemically etching a plurality of holes into a metallic bearing insert; and molding a body to the bearing insert to form an orthopaedic cutting block. ### Claim 15 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, wherein chemically etching the plurality of holes into the bearing insert comprises chemically etching each of the plurality of holes through the entire thickness of the bearing insert. ### Claim 16 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, wherein chemically etching the plurality of holes into the bearing insert comprises: forming a mask on the bearing insert, the mask defining a plurality of exposed areas; placing the bearing insert having the mask in a chemical bath whereby the plurality of exposed areas are chemically etched into the plurality of holes; removing the bearing insert having the mask from the chemical bath; and removing the mask from the bearing insert. ### Claim 17 (depends on 16) The method for manufacturing an orthopaedic surgical instrument of claim 16, wherein forming the mask on the bearing insert comprises: applying a photoresist material to the bearing insert; selectively exposing portions of the photoresist material to a light source using a patterned photomask; and selectively removing portions of the photoresist material using a developer to define the plurality of exposed areas on the bearing insert. ### Claim 18 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, wherein molding the body to the bearing insert comprises: loading the bearing insert into a mold, the bearing insert contacting a wall of the mold; and injecting a polymer into the mold such that the bearing insert is pressed against the wall of the mold by the polymer and the polymer at least partially fills the plurality of holes. ### Claim 19 (depends on 14) The method for manufacturing an orthopaedic surgical instrument of claim 14, wherein chemically etching the plurality of holes into the bearing insert further comprises chemically etching a groove into the bearing insert. ### Claim 20 (depends on 19) The method for manufacturing an orthopaedic surgical instrument of claim 19, further comprising bending the bearing insert along the groove prior to molding the body to the bearing insert.