Porous structures produced by additive layer manufacturing

Patent metadata

Field	Value
Publication number	US-12472679-B2
Application number	US-202318112809-A
Country	US
Kind code	B2
Filing date	Feb 22, 2023
Priority date	Jun 15, 2017
Publication date	Nov 18, 2025
Grant date	Nov 18, 2025

Abstract

A method of forming a tubular structure including a first tube and a second tube. The steps of the method include first successively depositing layers of a first material and at least partially melting at least a portion of each deposited layer of the first material at predetermined locations to form the first tube. Second, successively depositing layers of a second material and at least partially melting at least a portion of each deposited layer of the second material at additional predetermined locations to form the second tube, wherein the second tube is attached to the first tube at an intersection. Additionally, at least partially melting steps include forming portions of a plurality of segments, and the first tube and the second tube share segments of the plurality of segments at their intersection.

First claim

The invention claimed is:

1 . A method of forming a tubular structure including a first tube and a second tube comprising the steps of:
successively depositing layers of a first material and at least partially melting at least a portion of each deposited layer of the first material at predetermined locations to form the first tube; and successively depositing layers of a second material and at least partially melting at least a portion of each deposited layer of the second material at additional predetermined locations to form the second tube, wherein the second tube is attached to the first tube at an intersection, wherein the at least partially melting steps include forming portions of a plurality of segments, and wherein the first tube and the second tube share segments of the plurality of segments at their intersection.

2 . The method of claim 1 , wherein the at least partially melting steps include scanning the successively deposited layers of the first and the second materials with a high energy beam.

3 . The method of claim 2 , wherein either one or both of the first and the second materials are made of any one or any combination of plastic, metal, ceramic, and glass.

4 . The method of claim 1 , wherein the formed segments of the plurality of segments are attached to at least one other formed segment of the plurality of segments at vertices to define a plurality of open cells, the plurality of open cells forming a surface or surfaces of either one or both of the first tube and the second tube.

5 . The method of claim 4 , wherein the open cells form a reticulated configuration.

6 . The method of claim 4 , wherein the open cells are tessellated.

7 . The method of claim 6 , wherein the at least partially melting steps vary the size of the open cells such that the tubular structure has variable porosity.

8 . The method of claim 4 , wherein each of the open cells is bounded by a respective closed perimeter defined by only attached pairs of segments of the plurality of segments.

9 . The method of claim 4 , wherein the open cells define an aperture larger than the open cells.

10 . The method of claim 9 , wherein the aperture has a polygonal shape.

11 . The method of claim 4 , wherein a solid structure larger than each of the plurality of the open cells extends from multiple open cells of the plurality of the open cells, and wherein an entirety of the solid structure is bounded by segments of the multiple open cells.

12 . The method of claim 4 , further comprising the steps of:
depositing an additional material different from the first material with or within at least one of the deposited layers of the first material; and at least partially melting at least a portion of the deposited additional material at predetermined marker locations to form radiopaque markers, wherein the radiopaque markers, upon formation of the first tube and the second tube, either one or both of (i) are at a surface of either one or both of the first tube and the second tube or (ii) extend from either one or both of the first tube and the second tube.

13 . The method of claim 12 , wherein the additional material includes a predetermined amount of platinum corresponding to a desired level of radiopacity of the radiopaque markers.

14 . The method of claim 1 , wherein the tubular structure has an aperture with a boundary defined by segments of a plurality of the open cells.

15 . A method of forming a tubular structure comprising the steps of:
successively depositing layers of a first material and at least partially melting at least a portion of each deposited layer of the first material at predetermined locations to form a first tube; and wherein the first tube defines a central axis thereof, wherein the at least partially melting steps form an end portion and a main tube portion of the first tube, the end portion extending in a direction transverse to the central axis, and wherein a portion of a perimeter of the end portion is hingedly attached to the main tube portion.

16 . The method of claim 15 , wherein the at least partially melting steps include forming portions of a plurality of segments, and wherein the formed segments of the plurality of segments are attached to at least one other formed segment of the plurality of segments at vertices to define a plurality of open cells, the plurality of open cells forming a surface or surfaces of either one or both of the first tube and the second tube.

17 . The method of claim 15 , wherein the end portion comprises tessellated cells defining pores.

18 . The method of claim 15 , wherein the end portion is a solid plate.

19 . The method of claim 15 , wherein the end portion is attached to the main tube portion by closed links that pass through both the end portion and the main tube portion.

20 . The method of claim 15 , further comprising steps of successively depositing layers of a second material and at least partially melting at least a portion of each deposited layer of the second material at additional predetermined locations to form a second tube,
wherein the second tube is attached to the first tube at an intersection.

Assignees

• Howmedica Osteonics Corp

Inventors

• Stamp Robin
• Robinson Joseph
• Walsh Gearoid
• Lau Rachel King-Ha

Classifications

• B23K26/34

  Laser welding for purposes other than joining · CPC title

• B23K26/354

  by melting · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B22F10/20

  Direct sintering or melting · CPC title