Textured breast implant and methods of making same
First Claim
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1. A method for creating a textured breast implant, the method comprising:
- dipping a mandrel into a liquid elastomer to form a breast implant shell around the mandrel;
depositing, via a three-dimensional printing process, a texturing material onto the breast implant shell to form a first micrometer-scale pattern for creating an imprint on the breast implant shell;
curing the breast implant shell to form a first cured, imprinted layer;
removing the texturing material from the first cured, imprinted layer to form a textured surface;
applying a tacky layer onto the textured surface;
depositing, via three-dimensional printing, additional texturing material onto the tacky layer to form a second micrometer-scale pattern for creating a second imprint on the tacky layer;
curing the tacky layer to form a second cured, imprinted layer; and
removing the additional texturing material from the second cured, imprinted layer to obtain a second textured surface, the first and second cured, imprinted layers being configured to permit ingrowth of cells into the breast implant.
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Abstract
Methods for texturing surgical implants, for example, breast implants, are provided. The methods include the use of computer controlled 3D printing of a sacrificial material to create a textured surface on an unfinished surface of the implant.
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Citations
20 Claims
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1. A method for creating a textured breast implant, the method comprising:
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dipping a mandrel into a liquid elastomer to form a breast implant shell around the mandrel; depositing, via a three-dimensional printing process, a texturing material onto the breast implant shell to form a first micrometer-scale pattern for creating an imprint on the breast implant shell; curing the breast implant shell to form a first cured, imprinted layer; removing the texturing material from the first cured, imprinted layer to form a textured surface; applying a tacky layer onto the textured surface; depositing, via three-dimensional printing, additional texturing material onto the tacky layer to form a second micrometer-scale pattern for creating a second imprint on the tacky layer; curing the tacky layer to form a second cured, imprinted layer; and removing the additional texturing material from the second cured, imprinted layer to obtain a second textured surface, the first and second cured, imprinted layers being configured to permit ingrowth of cells into the breast implant. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method for creating a textured breast implant having a plurality of textured layers thereon, method comprising repeatedly, for each textured layer, performing the steps of:
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applying a tacky layer onto the implant; depositing, via a three-dimensional printing process, a texturing material in a predetermined pattern onto the tacky layer of the implant; curing the tacky layer; and removing the texturing material from the tacky layer to obtain a textured layer. - View Dependent Claims (12, 13, 14, 15)
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16. A method for creating a textured breast implant, the method comprising:
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dipping a mandrel into a liquid elastomer to form a breast implant shell around the mandrel; forming a first micrometer-scale pattern on the breast implant shell using sugar and a solid freeform fabrication (SFF) or layer manufacturing (LM) technique; curing the breast implant shell to form a first cured, imprinted surface; removing the sugar from the first cured, imprinted surface; after removing the sugar from the first cured, imprinted surface, applying a tacky layer onto the first cured, imprinted surface; forming a second micrometer-scale pattern on the tacky layer using sugar and a solid freeform fabrication (SFF) or layer manufacturing (LM) technique; curing the tacky layer to form a second cured, imprinted surface; and removing the sugar from the second cured, imprinted surface to obtain a second textured surface that facilitates cell ingrowth on the implant. - View Dependent Claims (17, 18, 19, 20)
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Specification