System and method of manufacture for spinal implant
AssigneeWarsaw Orthopedic, Inc.
InventorsDale A. Tempco, Rodney Ray Ballard, Matthew D. May
Life of this patent
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Abstract
A build plate includes a surface that defines at least one opening configured for disposal of a proximal portion of a screw shaft. The proximal portion is formed by a first manufacturing method and defines a distal face. The proximal portion is connected with the surface in a configuration to orient the distal face for forming a distal portion of the screw shaft thereon by a second manufacturing method that includes an additive manufacturing apparatus. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed.
Claims20
A method for fabricating a bone fastener, the method comprising the steps of:
- disposing a build plate with a working chamber of an additive manufacturing apparatus, the plate being substantially non-conductive and including at least one selectively oriented opening configured for disposal of a proximal portion of a screw shaft, the proximal portion defining a distal face;
- connecting the proximal portion with the plate in a configuration to orient the distal face for forming a threaded distal portion of the screw shaft thereon by the additive manufacturing apparatus based on selected configuration parameters;
- and
- forming the distal portion by heating a material in a layer by layer formation of the distal portion onto the distal face such that a processor instructs the additive manufacturing apparatus to form the distal portion onto the distal face such that the distal portion is made entirely from the material.
A method for fabricating a bone fastener, the method comprising the steps of:
- disposing a build plate with a working chamber of an additive manufacturing apparatus, the plate being substantially non-conductive and including at least one selectively oriented opening configured for disposal of a proximal portion of a screw shaft, the proximal portion defining a distal face;
- connecting the proximal portion with the plate in a configuration to orient the distal face for forming a threaded distal portion of the screw shaft thereon by the additive manufacturing apparatus based on selected configuration parameters;
- and
- forming the distal portion by applying a material in a layer by layer formation of the distal portion onto the distal face such that a processor instructs the additive manufacturing apparatus to form the distal portion onto the distal face such that the distal portion is made entirely from the material.
A method for fabricating a bone fastener, the method comprising the steps of:
- disposing a build plate with a working chamber of an additive manufacturing apparatus, the working chamber being defined an enclosure, the plate being non-conductive and including at least one selectively oriented opening configured for disposal of a proximal portion of a screw shaft, the proximal portion defining a distal face and comprising a first thread having a first pitch;
- connecting the proximal portion with the plate via a threaded engagement to orient the distal face such that the distal face is disposed in a flush orientation with a planar surface of the plate for forming a distal portion of the screw shaft thereon by the additive manufacturing apparatus based on selected configuration parameters such that the distal portion includes a second thread, the second thread having a second pitch, the second pitch being different than the first pitch;
- and
- forming the distal portion by moving the plate in a plurality of directions relative to the enclosure and applying a material in a layer by layer formation of the distal portion onto the distal face such that a processor instructs the additive manufacturing apparatus to form the distal portion onto the distal face such that the distal portion is made entirely from the material,
- wherein the at least one opening is selectively oriented to control distal portion thread formation, material deposition timing and/or material heating,
- wherein the additive manufacturing apparatus includes a laser device that melts and solidifies the material disposed onto the distal face in a selected three dimensional shape based on the selected configuration parameters.
Dependencies are inferred from the claim text.