US 9,517,136 B2 · Variable-density implants and related methods and systems

Abstract

Ceramic orthopedic implants may have one or more dense inner layers and one or more porous outer layers. Methods for manufacturing the implants may include one or more stages during which the dense inner layer(s) are partially compressed. At least one porous outer layer may include coating particles that are present at a surface of one or more inner layer(s) while pressure is applied to attach the coating particles to the inner layer(s) and to further compress one or more of the inner layer(s). Various layers may be formed until an implant, or other device, is formed having the desired density gradient and/or other properties, as disclosed herein.

Claims17

Dependent claims

A method for manufacturing a silicon nitride ceramic hip prosthesis, the method comprising the steps of:

performing a first isopressing process to form a base portion of a monolithic acetabular cup, wherein the base portion comprises a silicon nitride ceramic material at a first density;
performing a second isopressing process to form coating particles comprising a silicon nitride ceramic material;
combining the coating particles with the base portion in an isopress mold;
performing a third isopressing process on the combined base portion and coating particles to form a first layer of silicon nitride ceramic made up of the coating particles on the base portion, wherein the first layer comprises a second density, and wherein the second density is less than the first density;
and
firing the combined base portion and coating particles to form a monolithic acetabular cup for a hip prosthesis.

3 more elements

A method for manufacturing a ceramic biomedical implant, the method comprising the steps of:

coating a first set of particles with a silicon nitride ceramic powder to form a first set of coated particles, wherein the first set of particles comprise pore former cores configured to form pores in a silicon nitride ceramic material upon firing;
performing a first isopressing process to form a base of a ceramic biomedical implant, wherein the base comprises a first density;
applying the first set of coated particles to at least a portion of the base;
performing a second isopressing process on the base with the first set of coated particles to form a first layer, wherein the first layer comprises a second density, and wherein the second density is less than the first density;
and
firing the base and the first set of coated particles together to form a ceramic biomedical implant, wherein the step of firing the base and the first set of coated particles together causes the pore former cores to form pores in the first layer.

3 more elements

Dependencies are inferred from the claim text.

Variable-density implants and related methods and systems

Life of this patent

Variable-density implants and related methods and systems

Life of this patent

Abstract

Claims17