Laser-Produced Porous Surface

A method of producing a three-dimensional porous structure comprising the steps of:

• depositing a first layer of a metal powder onto a substrate;
• scanning a beam at least once over the first layer of metal powder to melt the deposited first layer so as to create at least two solid portions separated from one another and defining a pore having a required pore size within the porous structure;
• depositing successive layers of metal powder onto the first layer;
• and
• repeating the scanning steps for each of the successive layers until a desired height of the porous structure relative to the substrate is reached,
• wherein the metal powder is selected from the group consisting of titanium, titanium alloys, stainless steel, cobalt chrome alloys, tantalum and niobium,
• wherein the repeating steps form a plurality of pores having a pore size in a range from about 80 μm to 800 μm.

A method of producing an orthopedic implant comprising:

• depositing a first layer of a metal powder onto a substrate;
• scanning a beam at least once over the first layer of metal powder to melt the deposited first layer so as to create at least two solid portions separated from one another and defining a pore having a required pore size within the orthopedic implant;
• depositing successive layers of metal powder onto the first layer;
• and
• repeating the scanning steps for each of the successive layers to form a plurality of polygonal cells within the orthopedic implant. the scanning steps being repeated until a desired height of the orthopedic implant relative to the substrate is reached.