Implant Support Structure And Method Of Fabrication Of Implant Using The Same

A method of fabricating a build structure, comprising:

• sintering or melting a first set of layers of powder, successively, to fabricate a first portion or portions of a support structure supported by a build plate;
• applying a high energy beam to a second set of layers of powder, successively, (i) to sinter or melt a first portion or portions of the second set of layers of powder to fabricate a second portion or portions of the support structure supported by the first portion or portions of the support structure, (ii) to heat but no more than semi-sinter a second portion or portions of the second set of layers of powder, and (iii) to sinter or melt a third portion or portions of the second set of layers of powder to fabricate a first portion or portions of an in-process build structure such that the first portion or portions of the second set of layers of powder are spaced from the third portion or portions of the second set of layers of powder by the second portion or portions of the second set of layers of powder;
• and
• sintering or melting a third set of layers of powder, successively, to fabricate a second portion or portions of the in-process build structure supported by the first portion or portions of the in-process build structure.

An in-process build assembly, comprising:

• an in-process build structure;
• a support structure supporting the in-process build structure and surrounding a cross-section of the in-process build structure without surrounding an entirety of the in-process build structure;
• and
• semi-sintered particles located between the in-process build structure and the support structure such that there is no direct attachment of the in-process build structure to the support structure.