Hip joint prostheses and methods for manufacturing the same
AssigneeJohnson & Johnson Professional, Inc.
InventorSalvatore Caldarise
Life of this patent
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Abstract
An implantable bone prosthesis, such as an acetabular shell, includes a bone engaging region that is made from a cast metal or metal alloy and an articulation surface that is formed of a ceramic material or a metal that is permanently attached to the metal bone engaging region. The bone engaging region of the prosthesis preferably includes a dampening mechanism to absorb some of the loading forces communicated to the acetabular cavity. The bone prosthesis is formed by a casting process from casting molds that are prepared using a three dimensional printing technique.
Claims5
A method of forming an implantable article having a ceramic hemispherical cup-like structure permanently mounted within a metallic acetabular shell comprising the steps of:
- a) depositing a layer of a first, densely packed powder material in a confined region;
- b) applying a binder to selected regions of the first powder material to solidify the first powder material in a predetermined pattern;
- c) repeating steps (a) and (b) a predetermined number of times to form the hemispherical, cup-like structure, a smooth internal surface of which is configured to receive a femoral head component and serve as an articulation surface of the acetabular shell;
- d) depositing a layer of a second powder material in the confined region;
- e) applying a binder to selected portions of the second powder material contained within the confined region to solidify the powdered material in selected regions;
- f) repeating steps (d) and (e) a predetermined number of times to obtain successive layers of powder, with variations in regions to which binder is applied such that a solidified portion of each layer is bonded to a preceding layer and to the hemispherical, cup-like structure to form a casting mold that defines a negative of the implantable acetabular shell and includes, as an integral component thereof, the hemispherical, cup-like structure;
- g) removing loose, non-bonded powder material from within the casting mold;
- h) applying a casting material to the interior of the casting mold and allowing the casting material to form the solid acetabular shell and bond to the hemispherical, cup-like structure;
- and
- i) removing the acetabular shell from the casting mold such that the acetabular shell still has the hemispherical, cup-like structure permanently attached thereto.
Dependencies are inferred from the claim text.