Variable wall thickness interlocking intramedullary nail

Abstract

An intramedullary nail comprises a unitary piece of elongate material of tubular cross-section having variations in wall thickness along its length. The nail has a proximal portion, a distal portion and an intermediate portion between the proximal and distal portions. The wall thicknesses of the proximal and distal portions are substantially greater than the wall thickness of the intermediate portion. In preferred embodiments, the outside diameters of the proximal, intermediate and distal portions are substantially equal or, alternatively, the outside diameter of the proximal portion is larger than the substantially equal outside diameters of the distal and intermediate portions. The nail is provided with a longitudinal slot which preferably extends along substantially the entire length of the nail. The nail is also provided with transverse openings through the proximal and distal portions to receive interlocking screws, and a portion of the inside diameter of the proximal portion is threaded to provide a point of attachment for insertion and extraction devices. The invention further includes an advantageous method of making the nail from a single length of material, such as stainless steel tubing. The advantageous method includes the two-step process of machining the intermediate portion of the length of tubing to reduce the outside diameter and wall thickness thereof, while maintaining the inside diameter substantially constant, and swaging either the proximal portion or the distal portion (or both) to reduce the inside and outside diameters thereof, such that the wall thickness of the swaged portion is substantially greater than the wall thickness of the intermediate portion of the tubing. Another aspect of the invention is the provision of a cap for the internally threaded end of the proximal portion to prevent the ingrowth of tissue.