Methods and devices for trauma welding

A method for stabilizing a bone, the method comprising:

• positioning an elongate rod in the medullary canal of the bone;
• forming a passageway through the cortex of the bone, the passageway extending from the exterior surface of the bone to the medullary canal of the bone;
• positioning a fastener in the passageway of the cortex such that at least a leading portion of the fastener is in contact with a bonding region of the elongate rod, the bonding region generally aligned with the passageway of the cortex;
• and
• bonding the leading portion of the fastener to the bonding region of the elongate rod while the fastener is positioned in the passageway of the cortex,
• wherein the elongate rod and fastener include thermoplastic material and wherein ultrasonic energy is used to bond the fastener to the bonding region of the elongate rod,
• wherein forming a passageway and creating a bonding region includes drilling a hole completely through the bone and elongate rod,
• wherein positioning the fastener includes positioning the fastener in the drilled hole, and
• wherein bonding the fastener includes bonding the fastener to the elongate rod and to two cortex areas of the bone.

A method for stabilizing a bone, the method comprising:

• positioning an elongate member in the medullary canal of the bone, the elongate member having a bonding region including thermoplastic material;
• positioning a reinforcing member including thermoplastic material on a cortical surface of the bone such that the cortex of the bone is positioned between the elongate member and reinforcing member;
• forming a passageway through the reinforcing member and the cortex of the bone, the passageway extending from the exterior surface of the reinforcing member to the medullary canal of the bone;
• positioning a fastener having a leading portion including thermoplastic material in the passageway,. such that at least the leading portion of the fastener is in contact with the bonding region of the elongate member, the bonding region generally aligned with the passageway;
• and
• bonding the leading portion of the fastener to the bonding region of the elongate member by applying ultrasonic energy to the fastener at a distance away from the leading portion of the fastener, while the fastener is positioned in the passageway,
• wherein the leading portion of the fastener is positioned in an indentation in the elongate member and wherein the indentation extends only partially into the elongate member.

A method for stabilizing a long bone, the method comprising:

• positioning an elongate rod including thermoplastic material in the medullary canal of the long bone;
• positioning a fastener having thermoplastic material at a leading portion through the bone such that at least the leading portion of the fastener is in contact with the elongate rod, and at least a trailing portion of the fastener extends through a cortical surface of the long bone to a position exterior of the bone;
• positioning an end effector in contact with the trailing portion of the fastener exterior of the bone;
• applying ultrasonic energy with the end effector to the trailing portion of the fastener to cause thermal bonding of thermoplastic material of the leading portion of the fastener to the thermoplastic material of the elongate rod, with the ultrasonic energy;
• and
• changing the shape of the fastener during bonding of the fastener
• wherein the ultrasonic energy is generated by an ultrasonic energy generating system with a drive voltage and wherein the ultrasonic energy generating system includes a feedback system to monitor and control the drive voltage.