Manufacture of bone graft substitutes

A method of manufacturing a bone graft substitute comprising the steps of:

• obtaining a bone material;
• pulverizing said material to produce a granulated bone material;
• and
• subjecting said granulated bone material to a powder compaction process.

A method of manufacturing a shaped bone graft substitute from granulated bone material, said method comprising the steps of:

• providing a stationary lower punch and a moveable lower punch which is vertically moveable about the stationary lower punch, a moveable die having at least one cavity and positionable generally above the stationary lower punch, and a moveable upper punch;
• introducing the granulated bone material into the cavity;
• positioning the moveable die generally above the stationary lower punch;
• moving the moveable upper punch to pressably contact the material in opposition to the moveable lower punch and stationary lower punch;
• and
• moving the moveable lower punch to pressably contact the material in opposition to the moveable upper punch,
• whereby said moving steps form the material into the shaped bone graft substitute.

A method of manufacturing a shaped bone graft substitute from granulated bone material, said method comprising the steps of:

• introducing an amount of the granulated bone material into the cavity;
• providing a lower punch assembly, an upper punch assembly, and a moveable die positionable generally above the lower punch assembly;
• positioning the moveable die generally above the lower punch assembly;
• moving the lower punch assembly in opposition to the moveable upper punch to pressably contact the material;
• moving the upper punch assembly in opposition to the moveable lower punch to pressably contact the material,
• whereby said moving steps form the material into the shaped bone graft substitute.

An apparatus for shaping a bone graft substitute from granulated bone material, said apparatus comprising:

• a stationary lower punch having a top surface;
• a moveable lower punch vertically moveable about the stationary lower punch and having a top surface;
• a moveable die having at least one cavity and positionable generally above the stationary lower punch;
• and
• a moveable upper punch,
• such that said moveable upper punch moves in opposition to said moveable lower punch to pressably contact the material contained within the cavity, whereupon following pressably contacting the material by the moveable lower punch the top surface height of the lower moveable punch is above the top surface height of the stationary lower punch.

A method for manufacturing a bone graft substitute from granulated bone material, said method comprising the steps of:

• providing:
• a first punch assembly having a first contact surface configured to effect a relief profile onto a first surface of the granulated bone material;
• a second punch assembly having a second contact surface;
• and
• a moveable die having at least one cavity;
• introducing the bone material into the cavity;
• positioning the moveable die generally in alignment with the first punch assembly;
• moving at least a portion of the first punch assembly to pressably contact the material in opposition to the second punch assembly to effect the desired relief profile on the first surface thereof;
• and
• moving at least a portion of the second punch assembly to pressably contact the material in opposition to the first punch assembly,
• whereby said moving steps form the material into the shaped bone graft substitute.

A method for manufacturing a bone graft substitute from demineralized bone matrix material, said method comprising the steps of:

• providing:
• a first punch assembly having a first contact surface configured to effect a relief profile onto a first surface of the demineralized bone matrix material;
• a second punch assembly having a second contact surface;
• and
• a moveable die having at least one cavity;
• introducing the demineralized bone matrix material into the cavity;
• positioning the moveable die generally in alignment with the first punch assembly;
• moving at least a portion of the first punch assembly to pressably contact the material in opposition to the second punch assembly to effect the desired relief profile on the first surface thereof;
• and
• moving at least a portion of the second punch assembly to pressably contact the material in opposition to the first punch assembly,
• whereby said moving steps form the material into the shaped bone graft substitute.

An apparatus for manufacturing a bone graft substitute from a granulated bone material, said apparatus comprising:

• a first punch assembly having a first contact surface having a profile configured to effect a relief profile onto a surface of the bone material;
• a second punch assembly having a second contact surface, the second contact surface positioned in general alignment with the first contact surface;
• and
• a moveable die having at least one cavity, the moveable die being positionable generally in between the first and second punch assemblies.