The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit
The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
대표청구항▼
1. A method of producing a three-dimensional porous structure comprising: depositing a first layer of a metal powder onto a substrate;scanning a beam at least once over the first layer of metal powder to remelt the metal powder in order to create at least two solid portions separated from one anothe
1. A method of producing a three-dimensional porous structure comprising: depositing a first layer of a metal powder onto a substrate;scanning a beam at least once over the first layer of metal powder to remelt the metal powder in order to create at least two solid portions separated from one another so as to give a required pore size;depositing a second layer of metal powder onto the first layer; andrepeating the scanning steps for each successive layer until a desired height is reached. 2. The method according to claim 1, wherein during said step of repeating said scanning steps, at least one scan is carried out angled relative to another scan in order to develop an interconnecting or non-interconnecting porosity. 3. The method according to claim 1, wherein said substrate is a base or core made of a metal selected from the group consisting of titanium, titanium alloys, stainless steel, cobalt chrome alloys, tantalum and niobium, wherein said first layer is fused to said base or core. 4. The method according to claim 3, wherein said core is integral with said resultant porous structure and imparts additional physical properties to the overall construct. 5. The method according to claim 3, wherein said core is detached from a resultant porous surface buildup. 6. The method according to claim 3, wherein a third element is added between said base and said first layer of metal powder to form a bond coat on said substrate. 7. The method according to claim 1, wherein the beam is a laser beam. 8. The method according to claim 1, wherein the beam is an electron beam. 9. A method of producing a three-dimensional porous structure having a varying porosity comprising the steps of: depositing a first layer of a metal powder onto a substrate;scanning a beam having a power (P) for a period of time (μsec) with a point distance (μm), so as to melt said metal powder at predetermined locations to form portions of a plurality of predetermined unit cells within said metal powder layer;depositing at least one additional layer of metal powder onto said first layer;repeating the step of scanning a beam for at least one of said deposited metal powder layers in order to continue forming said portions of said predetermined unit cells; andvarying porosity within said three-dimensional porous structure by at least one of (i) forming a unit cell in one metal powder layer having at least one of (a) a different shape from a unit cell within a successive metal powder layer and (b) at least one strut having a different dimension from a corresponding strut of a unit cell of the same shape within a successive metal powder layer, and (ii) applying a random perturbation in any direction to vertices of the unit cells to randomize the geometry of the unit cells. 10. The method according to claim 9, wherein at least one layer of said metal powder has a thickness between 5 μm and 2000 μm. 11. The method according to claim 9, further comprising predetermining a porosity range for at least one deposited metal powder layer and scanning said at least one deposited metal powder layer in a manner to provide said deposited metal powder layer with a porosity within said porosity range. 12. The method according to claim 9, wherein at least some of said predetermined unit cells are a tetrahedron, a dodecahedron, or an octahedron. 13. The method according to claim 9, wherein the beam is a laser beam. 14. The method according to claim 9, wherein the beam is an electron beam. 15. The method according to claim 9, wherein said substrate is a base or core made of a metal selected from the group consisting of titanium, titanium alloys, stainless steel, cobalt chrome alloys, tantalum and niobium, and wherein said first layer is fused to said base or core. 16. The method according to claim 15, wherein said base or core is integral with said first layer and imparts additional physical properties to an overall construct. 17. The method according to claim 9, wherein at least some of said predetermined unit cells are truncated to provide a barb effect. 18. The method according to claim 9, wherein said produced three-dimensional porous structure is a spinal component. 19. The method according to claim 9, wherein said metal powder is selected from the group consisting of titanium, titanium alloys, stainless steel, cobalt chrome alloys, tantalum and niobium. 20. The method according to claim 9, wherein said produced three-dimensional porous structure is a tissue in-growth structure. 21. A method of producing a three-dimensional structure comprising the steps of: depositing a first layer of a metal powder onto a substrate;scanning a beam having a power (P) for a period of time (μsec) with a point distance (μm), so as to melt said metal powder at predetermined locations to form a portion of a plurality of predetermined unit cells within said metal powder layer, said predetermined unit cells having a plurality of struts with a length and a cross-section;depositing at least one additional layer of metal powder onto said first layer;repeating the step of scanning a beam for at least some of said additional deposited metal powder layers in order to continue forming said predetermined unit cells; andvarying porosity within said three-dimensional structure by at least one of (i) forming a unit cell in one metal powder layer having at least one of (a) a different shape from a unit cell within a successive metal powder layer and (b) at least one strut having a different dimension from a corresponding strut of a unit cell of the same shape within a successive metal powder layer, and ii) applying a random perturbation in any direction to vertices of the unit cells to randomize the geometry of the unit cells. 22. The method according to claim 21, wherein at least some of said struts have a cross-section which is circular or rectangular. 23. The method according to claim 21, wherein some of said struts intersect at a plurality of intersection points, further comprising sintering at least some of said intersection points after at least some of said scanning and depositing steps are completed. 24. The method according to claim 21, wherein during the step of scanning said metal powder layers, said laser beam is adjusted to modify said length of said struts of said predetermined unit cells. 25. The method according to claim 21, wherein at least some of said predetermined unit cells are deformed so as to drape over said substrate. 26. The method according to claim 21, wherein during the step of scanning said metal powder layers, said beam is adjusted to modify said cross-section of said struts of said predetermined unit cells. 27. The method according to claim 21, wherein at least some of said predetermined unit cells are offset from one another to allow at least some struts of said predetermined unit cells to overlap some struts of another predetermined unit cell. 28. The method according to claim 21, wherein at least some of said predetermined unit cells are in the shape of a regular polygon. 29. The method according to claim 21, further comprising prior to scanning said metal powder layer, predetermining a range of porosity for said metal powder layer and adjusting said beam so that said beam scans said metal powder layer to produce a layer of melted metal powder having a porosity within said predetermined range. 30. The method according to claim 29, wherein said beam is adjusted for scanning more than one metal powder layer without having to be adjusted again. 31. The method according to claim 21, wherein said metal powder layers are deposited and scanned in a manner to form a medical implant. 32. The method according to claim 31, further comprising varying said porosity throughout said medical implant to provide soft-tissue characteristics to said medical implant. 33. The method according to claim 21, wherein at least some of said predetermined unit cells have at least one of a shape that is not a regular polygon and a strut that has an irregular cross-sectional shape. 34. The method according to claim 21, wherein the beam is a laser beam. 35. The method according to claim 21, wherein the beam is an electron beam.
연구과제 타임라인
LOADING...
LOADING...
LOADING...
LOADING...
LOADING...
이 특허에 인용된 특허 (184)
Swarts Dale F. ; Rohr ; Jr. William L. ; Lin Steve T. ; Devanathan Thirumalai ; Krebs Steven L. ; Schoenle Paul D., Acetabular cup.
LaSalle David L. (Woonsocket RI) Flynn Timothy M. (Norton MA) Caldarise Salvatore (Hanson MA) Manginelli Richard P. (Milton MA), Bone prostheses with direct cast macrotextured surface regions and method for manufacturing the same.
Garg Rajeev ; Prud'Homme Robert K. ; Aksay Ilhan A. ; Janas Victor F. ; TenHuisen Kevor S. ; Huxel Shawn T., Controlled architecture ceramic composites by stereolithography.
Eugenia Ribeiro de Sousa Fidalgo Leitao GB; Joost Dick De Bruijn NL; Hai-Bo Wen NL; Klaas De Groot NL, Device for incorporation and release of biologically active agents.
David M. Keicher ; Clinton L. Atwood ; Donald L. Greene ; Michelle L. Griffith ; Lane D. Harwell ; Francisco P. Jeantette ; Joseph A. Romero ; Lee P. Schanwald ; David T. Schmale, Energy-beam-driven rapid fabrication system.
Gaylo Christopher M. ; Flamenbaum Walter ; Flamenbaum Miles J., Fabrication of tissue products with additives by casting or molding using a mold formed by solid free-form methods.
Mayer, Jorg; Aeschlimann, Marcel; Torriani, Laurent, Implant to be implanted in bone tissue or in bone tissue supplemented with bone substitute material.
Freitag Douglas W. (Brookeville MD) Beaman Joseph J. (Austin TX) Bourell David L. (Austin TX), Laser-directed fabrication of full-density metal articles using hot isostatic processing.
Ogle Matthew F. ; Holmberg William R. ; Schroeder Richard F. ; Guzik Donald S. ; Mirsch ; II M. William ; Bergman Darrin J. ; Finucane Hallie A. ; Tweden Katherine S., Medical article with adhered antimicrobial metal.
Buchman, Alisa; Payne, Raymond G.; Mendes, David G.; Sibony, Simha; Bryant, Robert G., Medical implants made of wear-resistant, high-performance polyimides, process of making same and medical use of same.
Lawrence Evans Brown ; Timothy Paul Fuesting ; Joseph Jefferson Beaman, Jr. ; Suman Das, Method and apparatus for making components by direct laser processing.
Amrich, Mark P.; Buturlia, Joseph; Lynch, Robert F.; Rolfe, Jonathan L., Method for producing undercut micro recesses in a surface, a surgical implant made thereby, and method for fixing an implant to bone.
Deckard Carl R. (1801 Pin Oak La. Round Rock TX 78681) Beaman Joseph J. (700 Texas Ave. Austin TX 78705) Darrah James F. (4906 Manchaca Austin TX 78745), Method for selective laser sintering with layerwise cross-scanning.
Shetty H. Ravindranath (Warsaw IN) Heldreth Mark A. (Mentone IN) Parr Jack E. (North Webster IN), Method of bonding titanium to a cobalt-based alloy substrate in an orthophedic implant device.
Ducheyne Paul (Bryn Mawr PA) Cuckler John (Haverford PA) Radin Shulamit (Cherry Hill NJ), Method of depositing calcium phosphate cermamics for bone tissue calcification enhancement.
Devanathan Deva ; Krebs Steve ; Lin Steve T. ; Panchison Clarence M. ; Morr James J., Method of making an orthopaedic implant having a porous metal pad.
Panchison Clarence M. ; Hawley Michael S. ; Shetty Ravindranath H. ; Compton Richard C., Method of making an orthopaedic implant having a porous metal pad.
deAngelis Alfredo O. (241 Freeman St. #1 Brookline MA 02146), Method of three-dimensional rapid prototyping through controlled layerwise deposition/extraction and apparatus therefor.
Bourell David L. (Austin TX) Marcus Harris L. (Austin TX) Barlow Joel W. (Austin TX) Beaman Joseph J. (Austin TX) Deckard Carl R. (Austin TX), Multiple material systems for selective beam sintering.
Bourell David L. (Austin TX) Marcus Harris L. (Austin TX) Barlow Joel W. (Austin TX) Beaman Joseph J. (Austin TX) Deckard Carl R. (Austin TX), Multiple material systems for selective beam sintering.
Devanathan Deva (Warsaw IN) Krebs Steve (Fort Wayne IN) Lin Steve T. (Fort Wayne IN) Panchison Clarence M. (Warsaw IN) Morr James J. (Leesburg IN), Orthopaedic implant and method of making same.
Bigliani Louis U. ; Flatow Evan L. ; Norman Delfreda L., Orthopaedic implant having an articulating surface with a conforming and translational surface.
Shimamune Takayuki (Tokyo JPX) Sato Hideo (Chiba JPX) Hosonuma Masashi (Kanagawa JPX), Process for providing titanium composite having a porous surface.
Pratt Clyde R. (Somis CA) Carignan Roger G. (Camarillo CA) Raggio Charles M. (Camarillo CA) Woznick Chuck P. (Oxnard CA), Prosthesis device fabrication.
Buechel Frederick F. (61 First St. South Orange NJ 07079) Pappas Michael J. (61 Gould Pl. Caldwell NJ 07006), Prosthesis with biologically inert wear resistant surface.
Spector Myron (Charleston SC) Kwiatkowski George T. (Greenbrook NJ) Smarock Walter H. (Somerville NJ) Michno ; Jr. Michael J. (Somerville NJ), Prosthetic devices having coatings of selected porous bioengineering thermoplastics.
Coggan William G. (Rochester MI) Culpepper ; Jr. Bertram C. (Trenton MI) Pozzo James A. (Troy MI) Sommer Michael J. (Rochester MI) Wilson Richard C. (W. Bloomfield MI), Siding panels.
Bates, Brian L.; Fearnot, Neal E.; Kozma, Thomas G.; Osborne, Thomas A.; Ragheb, Anthony O.; Roberts, Joseph W.; Voorhees, III, William D., Silver implantable medical device.
Dickens ; Jr. Elmer Douglas (Richfield OH) Lee Biing Lin (Broadview Heights OH) Taylor Glenn Alfred (Houston TX) Magistro Angelo Joseph (Brecksville OH) Ng Hendra (E. Cleveland OH) McAlea Kevin P. (A, Sinterable semi-crystalline powder and near-fully dense article formed therein.
Sang-Hun Kang ; Robert L. Wittenberg, System and method for reducing wireless telecommunications network resources required to successfully route calls to a wireline network.
Beaman Joseph J. (Austin TX) McGrath Joseph C. (Calistoga CA) Prioleau Frost R. R. (Piedmont CA), Thermal control of selective laser sintering via control of the laser scan.
Pomerantz Itzchak (18 Golomb Street Kefar Sava ILX) Gilad Shalev (22a Anshei Bereshit Street Hod Hasharon ILX) Dollberg Yehoshua (10 Shtruck Street Tel Aviv ILX) Ben-Ezra Barry (7 Simtat Arougot Rama, Three dimensional modelling apparatus.
Timm Jens Peter, Three-dimensional geometric bio-compatible porous engineered structure for use as a bone mass replacement or fusion augmentation device.
Narayanan Pallassana V. (Davie FL) Rowland Stephen M. (Miami FL) Stanley Kimberly D. (Miami FL), Treatment of metallic surfaces using radiofrequency plasma deposition and chemical attachment of bioactive agents.
Moore, Cowan H.; Theken, Randall R.; Fries, Christopher Lee; Lucas, Eric Montgomery; Barros, Richard, Medical implants having desired surface features and methods of manufacturing.
Moore, Cowan H.; Theken, Randall R.; Fries, Christopher Lee; Lucas, Eric Montgomery; Barros, Richard, Medical implants having desired surface features and methods of manufacturing.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.