Spinal implant and method of manufacture

Patent metadata

Field	Value
Publication number	US-10307194-B2
Application number	US-201715666281-A
Country	US
Kind code	B2
Filing date	Aug 1, 2017
Priority date	Aug 1, 2017
Publication date	Jun 4, 2019
Grant date	Jun 4, 2019

Abstract

A bone fastener includes a screw shaft having a proximal portion and a distal portion. The proximal portion is formed by a first manufacturing method and defines a distal face. The distal portion is formed onto the distal face by a second manufacturing method. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed.

First claim

What is claimed is:

1. A bone fastener comprising:
a screw shaft including a proximal portion and a distal portion,
the proximal portion being formed by a first manufacturing method and defining a distal face,
the distal portion being formed onto the distal face by a second manufacturing method.

2. A bone fastener as recited in claim 1 , wherein the distal face comprises a fabrication platform such that the distal portion is fused with the proximal portion by the second manufacturing method.

3. A bone fastener as recited in claim 1 , wherein the proximal portion is connectable with a part of an additive manufacturing apparatus to form the distal portion onto the distal face by the second manufacturing method.

4. A bone fastener as recited in claim 1 , wherein the second manufacturing method includes an additive manufacturing method.

5. A bone fastener as recited in claim 1 , wherein the second manufacturing method includes selective laser melting with a powder bed process to fabricate the distal portion onto the distal face.

6. A bone fastener as recited in claim 1 , wherein the distal face includes a planar configuration.

7. A bone fastener as recited in claim 1 , wherein the distal face includes an angled configuration.

8. A bone fastener as recited in claim 1 , wherein the distal portion is fabricated via the second manufacturing method based on a digital rendering of a selected implant configuration.

9. A bone fastener as recited in claim 1 , wherein the distal portion is fabricated via the second manufacturing method based on patient anatomy and surgical treatment.

10. A bone fastener as recited in claim 1 , wherein the distal portion is fabricated via the second manufacturing method to include a selected porosity.

11. A bone fastener as recited in claim 1 , wherein the distal portion is fabricated via the second manufacturing method to include cannulation.

12. A bone fastener as recited in claim 1 , wherein the distal portion is fabricated via the second manufacturing method to include a plurality of fenestrations.

13. A bone fastener as recited in claim 1 , wherein the distal portion is fabricated via the second manufacturing method to include a lock.

14. A bone fastener as recited in claim 1 , wherein the distal portion is fabricated via the second manufacturing method with a material including stainless steel, titanium, cobalt-chromium, polymers and/or silicone powder.

15. A bone fastener as recited in claim 1 , wherein the second manufacturing method includes a finishing process.

16. A bone fastener as recited in claim 1 , wherein the proximal portion is formed by the first manufacturing method to include a first thread form configuration and the distal portion is formed by the second manufacturing method to include a second thread form configuration.

17. A bone fastener as recited in claim 1 , wherein the first manufacturing method includes cutting, grinding, rolling, forming; molding, casting, forging, extruding and/or cold working.

18. A method for fabricating a bone fastener, the method comprising the steps of:
forming a proximal portion of a screw shaft of a bone fastener by a first manufacturing method, the proximal portion defining a distal face;
generating a digital representation of a configuration of a distal portion of the screw shaft;
storing the digital representation on a database coupled to a processor; and
forming the distal portion by a second manufacturing method that includes an additive manufacturing method such that the processor instructs an additive manufacturing apparatus to form the distal portion onto the distal face.

19. A method as recited in claim 18 , wherein the additive manufacturing method includes heating a material in a layer by layer formation of the distal portion onto the distal face.

20. A bone fastener comprising:
a head; and
a threaded shaft including a proximal portion and a distal portion,
the proximal portion being formed by a subtractive, deformative or transformative manufacturing method to include a first thread form and define a distal face,
the distal portion being formed onto the distal face in a layer by layer formation by an additive manufacturing method, the distal portion including a second thread form.

Assignees

• Warsaw Orthopedic Inc

Inventors

• Tempco Dale A
• Ballard Rodney Ray
• May Matthew D

Classifications

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• A61B17/8625 Primary

  Shanks, i.e. parts contacting bone tissue · CPC title

• A61F2002/30962

  using stereolithography · CPC title

• A61B2017/00004

  (bio)absorbable, (bio)resorbable or resorptive · CPC title

• B22F7/08

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title