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US 2026/0183447 A1Published application
Method for forming medical devices from a metal plate
AssigneeMiRus LLC
InventorNoah Roth
Life of this patent
Estimating the term…
Abstract
A method and process for manufacturing medical devices from a flat planar metal plate.
Claims6
A method and process for manufacturing medical devices wherein a portion or all of the formed medical device is formed of a metal alloy that includes at least 5 atomic percent of hafnium and/or rhenium;
- said method comprises:
- a. providing rhenium and/or hafnium powder and one or more metal powder additives selected from the group of molybdenum, calcium, chromium, cobalt, copper, gold, iron, magnesium, nickel, niobium, osmium, platinum, rare earth metals, rhenium, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, zinc, and/or zirconium, and/or a powder alloy of such metals;
- said metal powder particles are less than 1000 microns in size;
- b. consolidating said metal powder under pressure to form a green part or component;
- said step of consolidating occurs at a pressure of at least 400 Pa;
- c. sintering said green part or component;
- said step of sintering occurs at least 500° C. to at least partially fuse said metal powders together;
- said step of sintering is performed in a reduced oxygen atmosphere and/or under a vacuum;
- said sintered green part or component has an as-sintered average density of about 90-99% of a minimum theoretical density of a metal alloy formed from melting said metal powder;
- d. subjecting the green part or component to a swaging operation to form a metal plate;
- said swaging process reduces a cross-sectional area of said metal plate;
- said swaging process occurs at a temperature of at least 20° C. in a controlled neutral or non-reducing environment;
- e. annealing said metal plate;
- said step of annealing occurs in a reduced oxygen atmosphere and/or under a vacuum;
- f. cutting the metal plate to partially or fully form one or more medical devices from the metal plate;
- g. separating said one or more medical devices from said cut metal plate;
- h. smoothing and polishing said one or more medical devices;
- i. bending one or more of said medical devices into its final or near final shape;
- j. providing a coating material;
- said coating material is formed of a different material from said metal alloy;
- and
- k. coating said coating material on at least a portion of an outer surface of one or more of said medical devices.
19 more elements
A method and process for manufacturing medical devices wherein a portion or all of the formed medical device is formed of a metal alloy that includes at least 5 atomic percent of hafnium and/or rhenium;
- said method comprises:
- a. providing rhenium and/or hafnium powder and one or more metal powder additives selected from the group of molybdenum, calcium, chromium, cobalt, copper, gold, iron, magnesium, nickel, niobium, osmium, platinum, rare earth metals, rhenium, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, zinc, and/or zirconium, and/or a powder alloy of such metals;
- said metal powder particles are less than 1000 microns in size;
- b. consolidating said metal powder under pressure to form a green part or component;
- c. sintering said green part or component;
- d. cutting the metal plate to partially or fully form one or more medical devices from the metal plate;
- and
- e. bending one or more of said medical devices into its final or near final shape.
5 more elements
Dependencies are inferred from the claim text.