Metallic structures having porous regions from imaged bone at pre-defined anatomic locations

Patent metadata

Field	Value
Publication number	US-9993341-B2
Application number	US-201414475682-A
Country	US
Kind code	B2
Filing date	Sep 3, 2014
Priority date	Jul 20, 2012
Publication date	Jun 12, 2018
Grant date	Jun 12, 2018

Abstract

An additively manufactured medical implant, comprising a metallic body having at least one porous surface configured to promote bony on-growth or in-growth of tissue, the porous surface being replicated from a high resolution scan of bone, and a biological surface coating configured to create a barrier to particulate debris, the biological surface coating being produced from a titanium porous plasma spray surface coating or a biomimetic coating.

First claim

What is claimed is:

1. An additively manufactured medical implant, having a metallic body having at least one porous surface replicated from a high resolution scan of bone and configured to promote bony on-growth or in-growth of tissue and a biological surface coating on the porous surface forming a barrier against particulate debris, wherein the medical implant is produced from the steps of:
imaging bone with a high resolution digital scanner to generate a three-dimensional design model of the bone;
removing a three-dimensional section from the design model;
fabricating a porous region on a digital representation of the implant by replacing a solid portion of the digital implant with the section removed from the design model;
using an additive manufacturing technique to create the metallic body of a physical medical implant including a physical porous region corresponding to the fabricated porous region, wherein the physical porous region having at least one porous surface for promoting bony on-growth or ingrowth of tissue;
forming the biological surface coating on the porous surface of the metallic body by at least one of a titanium porous plasma spray process and a biomimetic process;
processing the biological surface coating with at least one of grit blasting, hyaluronic acid, an RGD-containing glycoprotein, and bend coating to enhance biological performance of the biological surface coating.

2. The additively manufactured medical implant of claim 1 , wherein the production step of imaging the bone with a high resolution digital scanner comprises scanning the bone with a computed tomography (CT) scanner.

3. The additively manufactured medical implant of claim 2 , wherein the production step of scanning the bone with a computed tomography (CT) scanner comprises scanning the bone with a MicroCT scanner.

4. The additively manufactured medical implant of claim 1 , further comprising the production step of modifying any artifacts from the three-dimensional design model of the bone.

5. The additively manufactured medical implant of claim 4 , wherein the production step of modifying any artifacts from the three-dimensional design model comprises removing defective regions of the design model containing non-uniformities or discontinuities by filling the defective regions with a selected and superimposed region of the bone model that does not contain a non-uniformity or a discontinuity.

6. The additively manufactured medical implant of claim 1 , further comprising the production step of converting the imaged bone to a digital file format.

7. The additively manufactured medical implant of claim 1 , wherein the production step of fabricating a porous region on a digital representation of the implant comprises utilizing a computer aided design (CAD) program to fabricate a porous region that structurally replicates the architecture of the bone, the porous region being selected from one of a hip, shoulder, knee, spine, elbow, wrist, ankle, finger and toe.

8. The additively manufactured medical implant of claim 1 , wherein the production step of using an additive manufacturing technique to create a physical implant comprises using a Direct Metal Laser Sintering (DMLS) process or an Electron Beam Melting (EBM) process, Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), Stereolithography (SLA), Laminated Object Manufacturing, Powder Bed and Inkjet Head 3D Printing and Plaster-Based 3D Printing (PP).

9. The additively manufactured medical implant of claim 1 , further comprising the production step of performing an additional manufacturing process on the physical implant to modify one or more features, the manufacturing process being selected from at least one of casting, molding, forming, machining, joining, polishing, blasting and welding.

10. An additively manufactured medical implant having a metallic body having at least one porous surface replicated from a high resolution scan of bone and configured to promote bony on-growth or in-growth of tissue and a biological surface coating on the porous surface forming a barrier against particulate debris, wherein the medical implant is produced from the steps of:
creating a digital image of the bone with a micro CT scanner;
removing any defective artifacts from the digital image;
converting the digital image to a three-dimensional design model of the bone;
removing a three-dimensional section that structurally replicates the architecture of the bone from the design model;
printing the removed design model section on a digital representation of the implant; and
creating the metallic body of a physical medical implant from the printed digital representation by using an additive manufacturing technique, the metallic body having the at least one porous surface;
forming the biological surface coating on the porous surface of the metallic body of the physical medical implant by at least one of a titanium porous plasma spray process and a biomimetic process; and
processing the biological surface coating with at least one of grit blasting, hyaluronic acid, an RGD-containing glycoprotein, and bend coating to enhance biological performance of the biological surface coating.

11. The additively manufactured medical implant of claim 10 , wherein the production step of printing the removed design model section on a digital representation of the implant comprises using a computer aided design (CAD) program to print the removed design model section.

12. The additively manufactured medical implant of claim 10 , wherein the production step of removing any defective artifacts comprises removing any defective regions containing a non-uniformity or discontinuity from the image by filling the defective regions with a selected and superimposed region of the digital image that does not contain a non-uniformity or a discontinuity.

13. The additively manufactured medical implant of claim 10 , wherein the production step of creating a physical implant from the printed digital representation by using an additive manufacturing technique comprises using a Direct Metal Laser Sintering (DMLS) process or an Electron Beam Melting (EBM) process, Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), Stereolithography (SLA), Laminated Object Manufacturing, Powder Bed and Inkjet Head 3D Printing and Plaster-Based 3D Printing (PP).

14. The additively manufactured medical implant of claim 10 , further comprising the production step of performing an additional manufacturing process on the physical implant to add one or more features, the manufacturing process being selected from at least one of casting, molding, forming, machining, joining, polishing, blasting and welding.

15. An additively manufactured medical implant to fill a bone void having a metallic body having at least one porous surface replicated from a high resolution scan of bone and configured to promote bony on-growth or in-growth of tissue and a biological surface coating on the porous surface forming a barrier against particulate debris, wherein the medical implant is produced from the steps of:
imaging a voided bone region with a high resolution digital scanner to generate a three dimensional design model of the voided bone region;
providing a digital representation of a non-voided bone region;
removing a three dimensional section of the non-voided bone region, the removed section having a size that substantially matches the size of the voided bone region;
creating the metallic body of a physical medical implant from the removed three dimensional section of the non-voided bone region by using an additive manufacturing techniqu

Assignees

• Biomet Mfg Llc

Inventors

• Vanasse Tom
• Gupta Gautam
• Meridew Jason

Classifications

• A61F2/30767

  Special external or bone-contacting surface, e.g. coating for improving bone ingrowth · CPC title

• Y10T29/49

  Method of mechanical manufacture · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• A61F2/30942 Primary

  for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques · CPC title