# US 12,097,657 B2 · Porous structures produced by additive layer manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,097,657 B2 - Document ID: US12097657B2 - Status: Granted - Kind: B2 - Application number: 16/781,693 - Filed: 2020-02-04 - Published: 2020-06-04 - Granted: 2024-09-24 - Earliest claimed: 2015-12-15 - Assignees: Howmedica Osteonics Corp. - Applicants: Howmedica Osteonics Corp. - Inventors: Thomas Francis McCarthy; Brock Miller; Robin Stamp; Yuri Zaitsev; Robert W. Klein; Marc Esformes; David Markel; Amit Mistry; Joseph Robinson - Web page: https://patentgrep.com/patent/US12097657B2 ## CPC - B29C 64/135: the energy source being concentrated, e.g. scanning lasers or focused light sources - A61F 2/0063: {Implantable repair or support meshes, e.g. hernia meshes} - A61L 27/56: Porous materials, {e.g. foams or sponges} - B22F 3/105: by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} - B22F 3/1103: {with particular physical characteristics} - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B22F 10/366: Scanning parameters, e.g. hatch distance or scanning strategy - B23K 26/342: Build-up welding - B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)} - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - A61F 2002/0068: {having a special mesh pattern} - A61F 2002/30914: {Details of the mesh structure, e.g. disposition of the woven warp and weft wires} - A61F 2002/30915: {made of a stack of bonded perforated sheets, grids or wire meshes} - B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures - B29L 2031/772: {Articles characterised by their shape and not otherwise provided for (closed loop B29L2031/709; ring-like B29L2031/7096; corrugated B29L2016/00, flat B29L2007/00; hollow B29L2022/00; screw-threaded B29L2001/00; toothed B29L2031/775; corrugated tubes B29L2023/18)} - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - Y02P 10/25: Process efficiency - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C) - A61L: METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES (preservation of bodies or disinfecting characterised by the agents employed A01N; preserving, e.g. sterilising, food or foodstuffs A23; preparations for medical, dental or toiletry purposes A61K) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations at least a first segment overlapping a second segment and underlapping a third segment is formed. ## Claims ### Claim 1 A porous tissue ingrowth implant comprising: a first mesh sheet; a second mesh sheet spaced apart from the first mesh sheet; and a first plurality of metallic links, each of the links of the first plurality of metallic links being attached to a first side of the first mesh sheet and to a first side of the second mesh sheet such that adjacent ones of the links of the first plurality of metallic links are separated by at least one pore defined by either the first mesh sheet or the second mesh sheet, wherein the first mesh sheet includes pores configured to prevent seepage of a bone cement therethrough. ### Claim 2 (depends on 1) The implant of claim 1, wherein either one or both of the first and the second mesh sheets include chain mail. ### Claim 3 (depends on 1) The implant of claim 1, wherein either one or both of the first and the second mesh sheets are in the form of a woven mesh. ### Claim 4 (depends on 1) The implant of claim 1, wherein at least the first mesh sheet has a rectangular profile, a triangular profile, a hexagonal profile, or a circular profile. ### Claim 5 (depends on 1) The implant of claim 1, wherein each of the links of the first plurality of metallic links forms a closed loop. ### Claim 6 (depends on 1) The implant of claim 1, wherein the first mesh sheet and the second mesh sheet are metallic. ### Claim 7 (depends on 1) The implant of claim 1, further comprising: a third mesh sheet; and a second plurality of metallic links, each of the links of the second plurality of metallic links being attached to a second side of the second mesh sheet and to a first side of the third mesh sheet such that adjacent ones of the links of the second plurality of metallic links are separated by at least one pore defined by either the second mesh sheet or the third mesh sheet. ### Claim 8 (depends on 7) The implant of claim 7, wherein each of the links of the second plurality of metallic links extends in a first direction and each of the links of the first plurality of metallic links extends in a second direction transverse to the first direction. ### Claim 9 (depends on 7) The implant of claim 7, wherein each of the links of both the first plurality of metallic links and the second plurality of metallic links extends in the same direction. ### Claim 10 (depends on 7) The implant of claim 7, further comprising: a fourth mesh sheet; a third plurality of metallic links, each of the links of the third plurality of metallic links being attached to a second side of the third mesh sheet and to a first side of the fourth mesh sheet such that adjacent ones of the links of the third plurality of metallic links are separated by a pore defined by either the third mesh sheet or the fourth mesh sheet; and a fourth plurality of metallic links, each of the links of the fourth plurality of metallic links being attached to a second side of the fourth mesh sheet and to a second side of the first mesh sheet such that adjacent ones of the links of the fourth plurality of metallic links are separated by at least one pore defined by either the fourth mesh sheet or the first mesh sheet. ### Claim 11 (depends on 10) The implant of claim 10, wherein the first side of the second mesh sheet is confronting and parallel to the first side of the first mesh sheet, the first side of the third mesh sheet is confronting and parallel to the second side of the second mesh sheet, and the first side of the fourth mesh sheet is confronting and parallel to the second side of the third mesh sheet. ### Claim 12 (depends on 7) The implant of claim 7, wherein the first side of the first mesh sheet defines a first edge, the first and the second sides of the second mesh sheet define a second edge and a third edge, respectively, and the first side of the third mesh sheet defines a fourth edge, wherein the first edge confronts and is parallel to the second edge, and wherein the third edge confronts and is parallel to the fourth edge. ### Claim 13 (depends on 12) The implant of claim 12, further comprising fourth and fifth mesh sheets, wherein edges of the first and the third mesh sheets confront and are parallel to respective edges of the fourth and the fifth mesh sheets. ### Claim 14 (depends on 7) The implant of claim 7, wherein each of the first mesh sheet, the second mesh sheet, and the third mesh sheet define respective vertices pointing towards a common center. ### Claim 15 A porous tissue ingrowth implant comprising: a first mesh section; a first plurality of metallic links; a second mesh section attached to the first mesh section via the first plurality of metallic links; a second plurality of metallic links; and a third mesh section attached to the second mesh section via the second plurality of metallic links, wherein each of the first, the second, and the third mesh sections have a different porosity than porosities defined by each of the first and the second plurality of metallic links, wherein the second mesh section is movable relative to the first mesh section about the first plurality of metallic links and the second mesh section is movable relative to the third mesh section about the second plurality of metallic links, and wherein the first, the second and the third mesh sections are spaced apart, and wherein the first mesh section includes pores configured to prevent seepage of a bone adhesive therethrough. ### Claim 16 (depends on 15) The implant of claim 15, wherein links of the first plurality of metallic links are attached to a first side of the first mesh section and to a first side of the second mesh section such that adjacent ones of the links of the first plurality of metallic links are separated by a pore defined by either the first mesh section or the second mesh section, and wherein links of the second plurality of metallic links are attached to a second side of the second mesh section and to a first side of the third mesh section such that adjacent ones of the links of the second plurality of metallic links are separated by at least one pore defined by either the second mesh section or the third mesh section. ### Claim 17 (depends on 15) The implant of claim 15, wherein the first plurality of links and the second plurality of links define different porosities. ### Claim 18 (depends on 15) The implant of claim 15, further comprising: a third plurality of links; a fourth plurality of links; and a fourth mesh section attached to the third mesh section via the third plurality of links and attached to the first mesh section via the fourth plurality of links, wherein the fourth mesh section is movable relative to the third mesh section about the third plurality of links and the fourth mesh section is movable relative to the first mesh section about the fourth plurality of links, and wherein the first, second, third, and fourth mesh sections are substantially rigid. ### Claim 19 A porous tissue ingrowth implant comprising: a first mesh sheet having a first plurality of metallic links; a second mesh sheet having a second plurality of metallic links; and a third plurality of metallic links, each of the links of the third plurality of metallic links being attached to the first mesh sheet and to the second mesh sheet and having either one or both of a different shape and a different size than the first and the second pluralities of metallic links, wherein the first and the second mesh sheets are spaced apart. ### Claim 20 (depends on 19) The implant of claim 19, wherein the third plurality of metallic links have a different diameter than the first plurality of metallic links and the second plurality of metallic links. ### Claim 21 (depends on 15) The implant of claim 15, wherein the first, the second, and the third mesh sections are metallic. ### Claim 22 (depends on 19) The implant of claim 19, wherein the first mesh sheet and the second mesh sheet are metallic. ### Claim 23 (depends on 19) The implant of claim 19, wherein the first mesh sheet is formed of segments corresponding to randomized unit cell structures within a porous CAD volume. ### Claim 24 (depends on 1) The implant of claim 1, wherein the first and the second mesh sheets are coplanar.