US 12,667,461 B1Granted

Sheet based triply periodic minimal surface implants for promoting osseointegration and methods for producing same

AssigneesRestor3D, Inc., Duke University

InventorsAndrew Todd Miller, Matthew Rexrode, Cambre Kelly, Ken Gall

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Abstract

Provided herein are implants and methods for producing implants. In at least one embodiment, the implants include sheet-based, triply periodic, minimal surface (TPMS) portions. According to one embodiment, the TPMS portions include a gyroid architecture that provides for improved osseointegration and mechanical performance over previous implants due to novel ratios of porosity to compressive strength, among other features. In one or more embodiments, the gyroid architecture is organized into unit cells that demonstrate anisotropic mechanical performance along an insertion direction. In various embodiments, the present methods include novel selective laser melting (SLM) techniques for forming the TPMS portions of implants in a manner that reduces defect formation, thereby improving compressive performance and other implant properties.

Claims18

Dependent claims

A 3D-printed spinal implant comprising:

a top surface, a bottom surface, a first side surface, a second side surface, a back surface, and a front surface;
a titanium, non-porous frame encompassing an outer perimeter of the top surface;
and
a porous sheet based triply periodic minimal surface portion:
integrally formed with the titanium frame via powder bed fusion;
comprising part of the top surface and extending from the top surface to the bottom surface;
and
defined by a plurality of unit cells, each unit cell comprising a base geometry defined by a base equation:
cos
⁢
x
⁢
sin
⁢
y
+
cos
⁢
y
⁢
sin
⁢
z
+
cos
⁢
z
⁢
sin
⁢
x
=
0
wherein:
at least one of the first side surface, the second side surface, the back surface and the front surface defines at least one opening for receiving instrumentation;
the porous sheet based triply periodic minimal surface portion is node and strut free;
the porous sheet based triply periodic minimal surface portion comprises a wall thickness of 0.25 mm to 1.0 mm;
the porous sheet based triply periodic minimal surface portion defines an opening devoid of any structure, the opening bisecting the porous sheet based triply periodic minimal surface portion;
and
the porous sheet based triply periodic minimal surface portion defined by the base equation comprising the part of the top surface is configured to directly contact bone of a patient upon implantation.

37 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/938,251Filed 5 Oct 2022 · continuation
Priority: 8 Jan 2020
Granted: 30 Jun 2026
Term ends: Not estimatedThe source records don’t support an estimate.

Classification15 codes

A61F 2/3094
Joints: designing or manufacturing processes
A61F 2/28
Prostheses implantable into the body: bones
A61F 2/30771
Special external or bone-contacting surface, e.g. coating for improving bone ingrowth: applied in original prostheses, e.g. holes or grooves
A61F 2/4455
For the spine, e.g. vertebrae or spinal discs: for the fusion of spinal bodies, e.g. intervertebral fusion of adjacent spinal bodies, e.g. fusion…

Family

Application16/737,341Parent of this continuation · filed 8 Jan 2020
Application16/991,638Parent of this continuation · filed 12 Aug 2020
US 10,772,732 B1Parent of this continuation · filed 15 Sep 2020
Application17/314,357Parent of this continuation · filed 7 May 2021
US 11,026,798 B1Parent of this continuation · filed 8 Jun 2021
US 11,484,413 B1Parent of this continuation
US 12,667,461 B1This patent

From the US filing history. Foreign family members aren’t listed.