Smith + Nephew

Smith & Nephew Orthopaedics Ag

Smith Nephew Asia Pacific Pte. Limited

Nephew Asia Pacific Pte. Limited

Smith & Newphew Plc

Vivek Devidas Pawar

Shilesh C Jani

Carolyn L Weaver

Gordon Bruce Hunter

Mark Lee Morrison

Abraham Biglari Salehi

Marcus Lee Scott

Lorenz Brunner

Daniel A Heuer

Jeffrey Joel Shea

Jason Sean Jordan

Roger Ryan Dees, Jr

Hamish Forster

Timothy John Band

Mark Ellsworth Nadzadi

John Rose

Forrest A James

Matthew J Quick

Donald E Kramer

Sean M Haddock

Dean Hughes

Stanley Tsai

Michael B Cooper

Jeff Shea

Lu Gan

Bob Jones

Dawn Ryan McLean

Zachary John Beers Post

Brad Dacus

Mark L Morrison

Daniel Allen Heuer

Mark Morrison

Tim Band

Medical devices, such as implants, and corresponding methods of manufacturing using an additive manufacturing technique, wherein the finished medical devices include a build plate retained therein, are disclosed. In some embodiments, the medical device includes a build plate having a plurality of peaks and a plurality of indentations, the plurality of peaks and the plurality of indentations together defining a surface roughness of an exterior surface of the build plate. The medical device may further include a first layer formed atop the exterior surface of the build plate, the first layer comprising a plurality of powder structures disposed over the plurality of peaks and the plurality of indentations. In some embodiments, an average peak distance between adjacent peaks of the plurality of peaks is less than an average width dimension of at least a portion of the plurality of powder structures.

Medical devices and methods for forming medical devices containing a build plate

An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.

Forming of additively manufactured product

There are provided herein methods and products resulting therefrom. The methods include attaching a pre-fabricated porous ingrowth structure to a substrate by applying heat, or creating and bonding an in-situ-formed porous ingrowth structure from beads on a substrate by applying heat. In some embodiments, an oxidized metal surface of the substrate is diffusion hardened during the heating process. In some embodiments, a vacuum is applied during the heating process. In some embodiments, pressure is applied during the heating process. Also provided herein are assemblies for compressing the pre-fabricated porous ingrowth structure or the beads onto the substrate during the heating process.

Methods and apparatuses for attachment of porous coatings to implants and products thereof

A medical implant is disclosed. The medical implant includes: a first biocompatible metal forming a substrate (), a second biocompatible metal diffused into the first biocompatible metal to form an biocompatible alloy surface (), the alloy surface further including a diffusion hardening species, wherein the diffusion hardening species may be carbon, nitrogen, oxygen, boron, or any combination thereof. A method of forming a medical implant is also disclosed. The method includes the steps of: providing a first biocompatible metal or alloy that forms a substrate (), providing a second biocompatible metal or alloy, diffusing the second biocompatible metal into the first biocompatible metal to form an alloy layer (), removing excess second metal material from the substrate to expose the alloy layer, and diffusion hardening the alloy layer.

Surface alloyed medical implant

A method of incorporating silver and/or copper into a biomedical implant includes: providing an implant having an outer surface; depositing silver and/or copper onto the outer surface of the implant; diffusing the silver and/or copper into a subsurface zone adjacent the outer surface; and oxidizing or anodizing the implant after the diffusion step to form an oxidized or anodized layer that contains at least some amount of elemental silver, elemental copper or silver or copper ions or compounds.

Biofilm resistant medical implant

A device, for example a medical implant, and a method of making the same, the device having a metal or metal alloy substrate, for example cobalt chrome, and a diffusion hardened metallic surface, for example a plasma carburized surface, contacting a non-diffusion hardened surface or a diffusion hardened surface having a diffusion hardening species different from that of the opposing surface.

Applications of diffusion hardening techniques

A composition and medical implant made therefrom, the composition including a thick diffusion hardened zone, and preferably further including a ceramic layer. Also provided are orthopedic implants made from the composition, methods of making the composition, and methods of making orthopedic implants from the composition.

Diffusion-hardened medical implant

The present disclosure provides methods to improve the properties of a porous structure formed by a rapid manufacturing technique. Embodiments of the present disclosure increase the bonding between the micro-particleson the surface of the porous structure and the porous structure itself without substantially reduce the surface area of the micro-particles. In one aspect, embodiments of the present disclosure improves the bonding while preserving or increasing the friction of the structure against adjacent materials.

Porous structures and methods of making same

Growing community of inventors

Germantown, TN, United States of America

Vivek Devidas Pawar