Laser-produced porous structure
AssigneesHowmedica Osteonics Corp., The University of Liverpool
InventorsEric Jones, Christopher J. Sutcliffe, Robin Stamp
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Abstract
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.
Claims20
A method of producing an orthopedic implant comprising the steps of:
- depositing a layer of a metal powder onto a substrate;
- scanning an energy beam so as to melt the metal powder layer deposited onto the substrate to form a plurality of points having a cross-sectional area, the points forming a first portion of a plurality of predetermined irregular unit cells within the metal powder layer deposited onto the substrate;
- depositing at least one additional layer of the metal powder onto the metal powder layer deposited onto the substrate;
- and
- performing additional scanning steps to form a plurality of additional points, the additional points forming additional portions of the plurality of predetermined irregular unit cells, the first portion and the formed additional portions collectively including one or more struts having a length and a substantially uniform cross-section along the length,
- wherein the one or more struts extend in an oblique direction with respect to the substrate, and
- wherein the geometries of the predetermined irregular unit cells vary.
A method of producing an orthopedic implant comprising the steps of:
- depositing a layer of a metal powder onto a substrate;
- scanning an energy beam so as to melt the metal powder layer deposited onto the substrate to form a first portion of a plurality of predetermined irregular unit cells within the metal powder layer deposited onto the substrate;
- depositing at least one additional layer of the metal powder onto the metal powder layer deposited onto the substrate;
- and
- performing additional scanning steps to form additional portions of the plurality of predetermined irregular unit cells, the first portion and the additional portions collectively forming one or more struts having a length and a substantially uniform cross-section along the length,
- wherein the one or more struts extends in an oblique direction with respect to the substrate,
- wherein the geometries of the predetermined irregular unit cells vary.
A method of producing an orthopedic implant comprising the steps of:
- depositing a layer of a metal powder onto a substrate;
- scanning an energy beam so as to melt the metal powder layer deposited onto the substrate to form a portion of a plurality of predetermined irregular unit cells within the metal powder layer deposited onto the substrate;
- depositing at least one additional layer of the metal powder onto the metal powder layer deposited onto the substrate;
- and
- performing additional scanning steps to form the plurality of predetermined irregular unit cells,
- wherein the geometries of the predetermined irregular unit cells vary.
Dependencies are inferred from the claim text.