Howmedica Osteonics Corporation

The University of Liverpool

Robert W Klein

Robin Stamp

Joseph Robinson

Matthew P Poggie

Nicholas Nai Guang Dong

Christopher John Sutcliffe

Eric Jones

Lewis Mullen

Dan Jones

Marc Esformes

Amit Mistry

Thomas Francis McCarthy

Brock Miller

Nicole Distefano

Yuri Zaitsev

Joe Robinson

David Markel

Aiguo Wang

Aaron Essner

Gearoid Walsh

Alvin Perez

Chau Ngo

Anthony Patrick Napolitano

Mark Esformes

John Scanlan

An implant is produced by fabricating first and second layers. The first layer of repeated and truncated building units is fused together to define pores. The second layer of repeated and truncated building units are fused together to define pores and fused onto the first layer of truncated building units. The first and the second layers form at least part of a porous portion of the implant. The formed porous portion is attached onto a base portion of an implant. The truncated building units of each of the first and the second layers are in the form of spatially overlapping three-dimensional shapes.

Additive manufacturing of porous coatings separate from substrate

Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a boundary is prepared. A space including the porous CAD volume is populated with unit cells. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. The space is populated with at least one elongated fixation element extending beyond the boundary to produce an interlocking feature enabling assembly or engagement with a mating structure.

Surface modified unit cell lattice structures for optimized secure freeform fabrication

A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations at least a first segment overlapping a second segment and underlapping a third segment is formed.

Porous structures produced by additive layer manufacturing

A packaging system includes a packaging unit and an article. The packaging unit includes a solid layer, a porous layer and a plastic layer with a cavity. The cavity is configured to receive and secure the article in an opening defined by the cavity that is flexible between a first and a second dimension. The packaging unit is fabricated by a 3D printing process. A tensioning device of a 3D printing machine tensions a feed filament during the 3D printing process.

Packaging structures and additive manufacturing thereof

A porous apparatus includes a first layer and a second layer. The second layer has a plurality of struts. At least some of the struts define a porous geometry defining a plurality of faces, at least one of the plurality of the faces at least partially confronting the first layer. Each face is bounded by intersecting struts at vertices. Less than all of the vertices of each face of the porous geometry at least partially confronting the first layer are connected by a strut to the first layer. A process of producing the at least partially porous structure includes depositing and scanning metal powder layers. At least some of the scanned metal powder layers form either one or both of a portion of a first section of the structure and a portion of a second section of the structure formed by at least the struts defining the porous geometry.

High fatigue strength porous structure

Porous tibial implant

One embodiment of the implant comprises a porous metal bone ingrowth portion () having a first side connected to a high density or solid (fully dense) metal portion () which in turn has an opposite side connected to a porous metal soft tissue ingrowth portion () thus forming a sandwich structure with the high density or fully dense portion in the middle. The implant may be made of a resorbable material such as an alloy of magnesium. Alternately, the alloy can be selected from the group consisting of calcium, iron, yttrium and lithium. The porous metal soft tissue ingrowth portion () has porosity characteristics allowing cartilage to interdigitate with the pores and extend outwardly beyond the platform of the metal surface towards a joint capsule. The solid or fully dense intermediate layermay have some porosity, however that porosity prevents either bone tissue or cartilage tissue from migrating therethrough.

Platform for soft tissue attachment

A temporary femoral implant system has a porous mold and a femoral component. The system fits at least partially in a femoral cavity. The mold has a wall with an interior surface and an exterior surface forming an interior space for receiving an antibiotic bone cement. The mold allows the antibiotic to diffuse through the wall to the exterior surface. The femoral component has a stem portion received within the mold. A method of using the implant system includes providing an implant system comprising a mold and a femoral component, inserting the mold into the femoral cavity with the exterior surface facing the femoral cavity, inserting the stem portion of a femoral component into the interior space of the mold and filling the interior space of the mold with an antibiotic bone cement.

Antibiotic bone cement spacer

Growing community of inventors

Orangeburg, NY, United States of America

Robert W Klein