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

Abstract

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.