# US 2014/0194858 A1 · Manufacturing method and product

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- Number: US 2014/0194858 A1
- Document ID: US20140194858A1
- Status: Published application
- Kind: A1
- Application number: 14/006,697
- Filed: 2012-02-14
- Published: 2014-07-10
- Earliest claimed: 2011-03-23
- Assignees: Depuy (Ireland)
- Inventors: Duncan Beedall; Mark Reason
- Web page: https://patentgrep.com/patent/US20140194858A1

## CPC

- B29C 45/16: Making multilayered or multicoloured articles {(B29C45/0062 takes precedence; feeding colouring materials into the injection unit B29C45/1816)}
- A61L 31/14: Materials characterised by their function or physical properties {, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials}
- B29C 2045/1682: {preventing defects}
- B29L 2031/7532: {Artificial members, protheses}
- B29L 2031/7546: {Surgical equipment}
- 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)
- 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)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A method of manufacturing a surgical instrument or prosthesis and a surgical instrument or prosthesis so manufactured are described. A first material is injected into a first mould to form an interim component. Portions of the interim component define at least one channel. The maximum wall thickness of the interim component is less than a first threshold determined by the injection moulding properties of the first material. The maximum width of the at least one channel is less than a second threshold determined by the injection moulding properties of a second material. The second material is injected into a second mould containing at least part of the channel of the interim component so that the channel is at least partially filled with the second material.

## Claims

### Claim at position 1

1-11. (canceled)

### Claim 12

A method of manufacturing a surgical instrument or prosthesis comprising a first material and a second material, the method comprising the following steps:
injecting the first material into a first mold to form an interim component having a plurality of walls, portions of the interim component defining at least one channel, the maximum wall thickness of the plurality of walls being less than 5 mm, and the maximum width of the at least one channel being less than 5 mm; and
injecting the second material into a second mold containing at least part of the channel of the interim component until the channel is at least partially filled with the second material.

### Claim 13 (depends on 12)

The method of claim 12, wherein the interim component comprises at least two ribs each having a thickness less than 5 mm, the at least one channel being defined between the ribs.

### Claim 14 (depends on 12)

The method of claim 12, wherein the interim component and the second mold are arranged such that the maximum width of the cavity between the interim component and the mold wall is less than 5 mm.

### Claim 15 (depends on 1)

The method of claim 1, wherein at least one of the first material and the second material further comprise at least one additive.

### Claim 16 (depends on 1)

The method of claim 1, wherein the first material and the second material comprises a high or ultra high performance polymer.

### Claim 17 (depends on 1)

The method of claim 1, wherein the method is a method of manufacturing an impactor.

### Claim 18

An injection molded surgical instrument or prosthesis, comprising:
a body having a minimum thickness which exceeds 5 mm;
wherein the body is formed in a two shot injection molding process using a first material and a second material, the body comprising interlaced portions of said first and second materials arranged such that the maximum thickness of any portion of the first material is less than 5 mm and the maximum thickness of any portion of the second material is less than 5 mm, and wherein the first material and the second material comprise the same plastic.