# US 2018/0021136 A1 · Rapid manufacturing of porous metal prostheses

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- Number: US 2018/0021136 A1
- Document ID: US20180021136A1
- Status: Published application
- Kind: A1
- Application number: 15/721,998
- Filed: 2017-10-02
- Published: 2018-01-25
- Earliest claimed: 2011-07-13
- Assignees: Zimmer, Inc.
- Applicants: Zimmer, Inc.
- Inventors: Jia Li; Adam M. Griner
- Web page: https://patentgrep.com/patent/US20180021136A1

## CPC

- A61F 2/28: Bones
- A61L 27/04: Metals or alloys
- A61L 27/56: Porous materials, {e.g. foams or sponges}
- B05D 1/12: Applying particulate materials (B05D1/06, B05D1/10 take precedence)
- B05D 3/0254: {After-treatment}
- B05D 5/00: Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- 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 3/11: Making porous workpieces or articles
- B33Y 80/00: Products made by additive manufacturing
- Y02P 10/25: Process efficiency
- 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)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- 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
- 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

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.

## Claims

### Claim 1

A method of rapidly manufacturing an orthopaedic prosthesis having a porous substrate, the porous substrate including an outer surface and a plurality of ligaments that define pores beneath the outer surface, the method comprising the steps of:
depositing a plurality of metal powder particles onto the outer surface of the porous substrate;
allowing at least a first portion of the plurality of metal powder particles to enter the pores beneath the outer surface of the porous substrate, the first portion of the plurality of metal powder particles being sized to fit within the pores of the porous substrate; and
applying an energy source to the first portion of the plurality of metal powder particles to form solid metal, the solid metal interdigitating into the pores of the porous substrate.