Method and apparatus for manufacturing an implant

An orthopedic device manufacturing method comprising:

• preparing pre-operatively a three-dimensional image of a patient's joint from imaging scans of the patient using computer modeling;
• selecting pre-operatively a non-custom femoral implant closely matching the joint and having a plurality of planar surfaces corresponding to planned planar resections of a femoral bone of the joint, the planned resections including an anterior cut plane, anterior chamfer plane, distal cut plane, posterior chamfer plane and posterior cut plane;
• manufacturing pre-operatively a customized femoral implant by a machining operation, the machining operation modifying at least six angles of the plurality of planar surfaces of the femoral implant to be patient-specific as determined from the three-dimensional image of the patient's joint, each patient-specific angle defined between a central plane perpendicular to a medial-lateral width of the femoral implant and lines connecting medial end points at medial edges between the planar resections and lateral points at lateral edges between the planar resections;
• manufacturing a patient-specific femoral alignment guide;
• coupling a removable tracking tag to the patient-specific femoral alignment guide for tracking the alignment guide from manufacture to surgery, the tracking tag including patient-specific information and configured to be removed prior to a corresponding surgical procedure;
• and
• preparing a surgical kit including the femoral implant and a patient-specific alignment guide for the surgical procedure.