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US 12,042,966 B2Granted
Forming of additively manufactured product
AssigneeSmith & Nephew, Inc.
InventorsVivek Pawar, Mark Morrison, Carolyn Weaver
Life of this patent
Estimating the term…
Abstract
An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.
Claims15
A method, comprising:
- manufacturing an initial part, which comprises a porous portion that has an initial porosity characteristic;
- mechanically deforming, at least partially, the porous portion of the initial part to form a deformed part that has a deformed layer having a region with a reduced porosity characteristic;
- and
- forming an orthopedic device from the deformed part by:
- placing at least a portion of the deformed part in a cavity of a mold, such that the deformed layer faces the cavity;
- and
- infiltrating a polymeric composition into pores of the region of the deformed layer, to provide a molded part that comprises the deformed part and an attached part;
- wherein the attached part is securely fixed to the deformed part by the infiltration of the polymeric composition into the pores of the region of the deformed layer.
5 more elements
A method comprising:
- manufacturing an initial part using an additive manufacturing procedure that includes melting a powder having a powder diameter to form a melt pool having a melt pool diameter, wherein the initial part comprises a first porous portion that has an initial porosity characteristic;
- mechanically deforming at least a portion of the initial part by striking the initial part to form a deformed part that has a deformed region, the deformed region including a deformed layer having a reduced porosity characteristic;
- and
- forming an orthopedic device from the deformed part;
- wherein the reduced porosity characteristic is selected based at least in part upon a first criterion and the initial porosity characteristic is selected based at least in part upon the reduced porosity characteristic and a second criterion;
- wherein the first criterion relates to a desired characteristic of the deformed layer;
- wherein the reduced porosity characteristic includes a target pore size;
- wherein the initial porosity characteristic includes an initial pore size;
- wherein the second criterion relates to a threshold pore size;
- wherein selecting the initial porosity characteristic based upon the reduced porosity characteristic and the second criterion includes selecting the initial pore size greater than each of the target pore size and the threshold pore size;
- wherein the threshold pore size corresponds to at least one of the powder diameter and the melt pool diameter;
- wherein the target pore size is less than the threshold pore size;
- and
- wherein the initial pore size is greater than the threshold pore size.
11 more elements
Dependencies are inferred from the claim text.