Medical devices and methods for forming medical devices containing a build plate

A method of forming a medical device, comprising:

• providing a build plate, the build plate having a plurality of peaks and a plurality of indentations, the plurality of peaks and the plurality of indentations together defining a surface roughness of an exterior surface of the build plate;
• and
• forming a first layer atop the exterior surface of the build plate by:
• depositing a plurality of powder structures over the plurality of peaks and within the plurality of indentations, at least a portion of the plurality of powder structures having an average width dimension that is greater than an average peak distance between adjacent peaks of the plurality of peaks;
• and
• heating the plurality of powder structures, wherein the first layer covers the plurality of peaks.

A method of forming an implant, comprising:

• providing a build plate, the build plate having a plurality of alternating peaks and indentations, the plurality of alternating peaks and indentations together defining a surface roughness of an exterior surface of the build plate;
• and
• forming a first layer atop the exterior surface of the build plate by:
• depositing a plurality of powder structures over the plurality of alternating peaks and indentations, at least a portion of the plurality of powder structures having an average width dimension that is greater than an average peak distance between adjacent peaks of the plurality of alternating peaks and indentations;
• and
• heating the plurality of powder structures, wherein the first layer entirely covers the plurality of alternating peaks and indentations.