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US 2015/0173903 A1Published application
Rapid manufacturing of porous metal prostheses
AssigneeZimmer, Inc.
InventorsJia Li, Adam M. Griner
Life of this patent
Estimating the term…
Abstract
An orthopaedic prosthesis and a method for rapidly manufacturing the same are provided. The orthopaedic prosthesis includes a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. A laser sintering technique is performed to manufacture the orthopaedic prosthesis.
Claims23
1-20. (canceled)
A method of manufacturing an orthopedic implant utilizing a highly porous substrate, comprising:
- providing a highly porous substrate with a porosity between 55% and 90%, the highly porous substrate including an outer surface and a plurality of ligaments that comprise metal and define pores therebetween;
- depositing a first plurality of metal powder particles onto the outer surface of the highly porous substrate, wherein at least a portion of the first plurality of metal powder particles falls into pores beneath the outer surface of the highly porous substrate;
- applying an energy source to the first plurality of metal powder particles such that the first plurality of metal powder particles melt and bond together to form a first region of a solid metal component that is at least partially received in pores beneath the outer surface of the highly porous substrate;
- depositing a second plurality of metal powder particles onto the first region of the solid metal component;
- and
- applying an energy source to the second plurality of metal powder particles such that the second plurality of metal powder particles melt and bond together to form a second region of the solid metal component bonded to the first region of the solid metal component.
3 more elements
A method of manufacturing an orthopedic implant utilizing a highly porous substrate, comprising:
- providing a highly porous substrate with a porosity between 55% and 90%, the highly porous substrate including an outer surface and a plurality of ligaments that comprise metal and define pores therebetween;
- delivering a first plurality of metal powder particles into a first exposed pore beneath the outer surface of the highly porous substrate so as to partially fill the first exposed pore with the first plurality of metal powder particles;
- applying an energy source to the first plurality of metal powder particles in the first exposed pore such that the first plurality of metal powder particles melt and bond together to form a first region of a solid metal component;
- delivering a second plurality of metal powder particles into the first exposed pore and onto the first region of the solid metal component;
- and
- applying an energy source to the second plurality of metal powder particles in the first exposed pore such that the second plurality of metal powder particles melt and bond together to form a second region of the solid metal component bonded to the first region of the solid metal component.
3 more elements
A method of manufacturing an orthopedic implant utilizing a highly porous substrate, comprising:
- providing a highly porous substrate with a porosity between 55% and 90%, the highly porous substrate including an outer surface and a plurality of ligaments that comprise metal and define pores therebetween;
- depositing a plurality of metal powder particles onto the highly porous substrate such that a first portion of the plurality of metal powder particles falls into pores beneath the outer surface of the highly porous substrate and a second portion of the plurality of metal powder particles remains outside the highly porous substrate beyond the outer surface of the highly porous substrate, wherein said depositing occurs over multiple separate depositing steps;
- and
- applying an energy source to the plurality of metal powder particles over multiple separate energy application steps, wherein said multiple separate energy application steps melts and bonds together the plurality of metal powder particles to form a continuous solid metal component that includes a first portion extending into pores beneath the outer surface of the highly porous substrate and a second portion providing a solid metal layer outside the highly porous substrate beyond the outer surface of the highly porous substrate.
1 more element
A method of manufacturing an orthopedic implant utilizing a highly porous substrate, comprising:
- providing a highly porous substrate with a porosity between 55% and 90%, the highly porous substrate including an outer surface and a plurality of ligaments that comprise metal and define pores therebetween;
- depositing a first layer of metal powder particles onto the outer surface of the highly porous substrate, wherein at least part of said first layer falls into pores beneath the outer surface of the highly porous substrate;
- applying an energy source to at least a first portion of said first layer such that metal powder particles of said first layer melt and bond together to form a first region of a solid metal component that is at least partially received in pores beneath the outer surface of the highly porous substrate;
- enlarging the solid metal component, said enlarging including depositing a subsequent layer of metal powder particles over the first region of the solid metal component and applying an energy source to at least a first portion of said subsequent layer such that metal powder particles of said subsequent layer melt and bond together to form a subsequent region of the solid metal component over said first region;
- and
- repeating said enlarging step until said solid metal component provides a solid metal layer outside the highly porous substrate beyond the outer surface of the highly porous substrate.
3 more elements
Dependencies are inferred from the claim text.