Composite joint arthroplasty systems and methods

• US 10,456,143 B2
• Filed: 06/16/2017
• Issued: 10/29/2019
• Est. Priority Date: 03/02/2017
• Status: Active Grant

• Current Assignee: Optimotion Implants LLC
• Original Assignee: Titanium Fusion Technologies, LLC
• Inventors: Justin, Daniel F., nguyen, Vuong binh, Medlin, Dana J.
• Primary Examiner(s): Pellegrino, Brian E
• Assistant Examiner(s): Zimmerman, Rebecca Lynee
• Application Number:
  US15/625,802
• Publication Number:
  US 20180250134A1
• Time in Patent Office: 865 Days
• Field of Search: 623 2015
• CPC Class Codes: A61B 17/142 with reciprocating saw blades, e.g. with cutting edges at the distal end of the saw blades
• CPC Class Codes: A61B 17/154 for preparing bone for knee prosthesis
• CPC Class Codes: A61B 17/155 Cutting femur
• CPC Class Codes: A61B 17/157 Cutting tibia
• CPC Class Codes: A61B 17/1675 for the knee
• CPC Class Codes: A61B 17/1764 for the knee
• CPC Class Codes: A61B 2017/568 produced with shape and dimensions specific for an individual patient
• CPC Class Codes: A61F 2/30744 End caps, e.g. for closing an endoprosthetic cavity
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/30771 applied in original prostheses, e.g. holes or grooves
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2/461 of knees
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30331 made by longitudinally pushing a protrusion into a complementarily-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2002/30332 Conically- or frustoconically-shaped protrusion and recess
• CPC Class Codes: A61F 2002/30448 using adhesives
• CPC Class Codes: A61F 2002/30451 soldered or brazed or welded
• CPC Class Codes: A61F 2002/305 Snap connection
• CPC Class Codes: A61F 2002/30604 : modular
• CPC Class Codes: A61F 2002/30818 : castellated or crenellated
• CPC Class Codes: A61F 2002/3084 : Nanostructures
• CPC Class Codes: A61F 2002/30841 : Sharp anchoring protrusions for impaction into the bone, e.g. sharp pins, spikes
• CPC Class Codes: A61F 2002/30845 : with cutting edges
• CPC Class Codes: A61F 2002/30878 : with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30884 : Fins or wings, e.g. longitudinal wings for preventing rotation within the bone cavity
• CPC Class Codes: A61F 2002/3092 : having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/3093 : for promoting ingrowth of bone tissue
• CPC Class Codes: A61F 2002/30968 : Sintering
• CPC Class Codes: A61F 2002/3097 : using laser
• CPC Class Codes: A61F 2002/30985 : using three dimensional printing [3DP]
• CPC Class Codes: A61F 2310/00023 : Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 : Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: A61F 2310/00059 : Chromium or Cr-based alloys
• CPC Class Codes: A61F 2310/00383 : Gelatin
• CPC Class Codes: B22F 10/00 : Additive manufacturing of workpieces or articles from metallic powder apparatus or devices therefor B22F12/00
• CPC Class Codes: B22F 10/28 : Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 2207/17 : density or porosity gradients
• CPC Class Codes: B22F 2998/10 : Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 : Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/11 : Making porous workpieces or articles
• CPC Class Codes: B22F 5/00 : Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
• CPC Class Codes: B22F 7/062 : involving the connection or repairing of preformed parts
• CPC Class Codes: B22F 7/08 : with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A prosthesis may have an articulating component formed via casting and a 3D printed bone anchoring component with a joint-facing side and a bone-facing side. The bone-facing side may have a bone engagement surface with a porous structure with pores selected to facilitate in-growth of the bone into the pores. The bone facing side may further have a surface layer of Titanium Dioxide nanotubes. The joint-facing side may be secured to the articulating component by melting Titanium nanoparticles at a temperature below the melting temperatures of the major constituents of the articulating component and/or the bone anchoring component, such as Cobalt, Chromium, and/or Titanium, so as to avoid significantly modifying the crystalline structures of the articulating component and/or the bone anchoring component. The melting temperature of the Titanium nanoparticles may be about 500° C.

Claims

1. A method for manufacturing a prosthesis for replacing an articular surface on a bone, the method comprising:

casting an articulating component comprising;

an articulating component joint-facing side comprising an articular surface; and

an articulating component bone-facing side comprising a bone-facing shape; and

fabricating a bone anchoring component with a porous structure, comprising;

a bone anchoring component joint-facing side comprising a joint-facing shape that is complementary to the bone-facing shape; and

a bone anchoring component bone-facing side comprising a bone engagement surface having a porous structure with pores selected to facilitate in-growth of the bone into the pores; and

securing the bone anchoring component joint-facing side to the articulating component bone-facing side by;

applying Titanium-based nanoparticles between the articulating component bone-facing side and the bone anchoring component joint-facing side; and

heating the Titanium-based nanoparticles to a temperature sufficient to melt the Titanium-based nanoparticles, but insufficient to melt the articulating component or bone anchoring component.

2. The method of claim 1, wherein fabricating the bone anchoring component comprises direct metal laser sintering Titanium to form a porous structure.

3. The method of claim 1, further comprising anodizing the bone anchoring component to form a surface layer of Titanium Dioxide nanotubes on the bone anchoring component joint-facing side.

4. The method of claim 3, further comprising heating the bone anchoring component to a temperature sufficient to change at least a portion of the surface layer of Titanium Dioxide nanotubes to anatase.

5. The method of claim 1, wherein:

casting the articulating component comprises casting the articulating component from an alloy of Cobalt Chromium to establish one or more crystalline structures of the alloy of Cobalt Chromium; and

heating the Titanium-based nanoparticles to the temperature comprises heating at least part of the bone anchoring component and at least part of the articulating component to a bonding temperature below melting temperatures of Cobalt and Chromium, so as to leave the crystalline structures intact.

6. The method of claim 5, wherein heating the Titanium-based nanoparticles comprises:

placing the articulating component, the bone anchoring component, and the Titanium-based nanoparticles in a furnace; and

in the furnace, heating the articulating component, the bone anchoring component, and the Titanium-based nanoparticles to the temperature.

7. The method of claim 5, wherein heating at least part of the bone anchoring component and part of the articulating component to the bonding temperature comprises laser welding a perimeter and/or seams of the bone anchoring component joint-facing side and the articulating component bone-facing side together.

8. The method of claim 5, further comprising, prior to heating at least part of the bone anchoring component and part of the articulating component to the bonding temperature, applying a paste to one or both of the bone anchoring component joint-facing side and the articulating component bone-facing side, the paste comprising the Titanium-based nanoparticles and a gelatin and/or a glycerin.

9. The method of claim 8, further comprising, after applying the paste on one or both of the bone anchoring component joint-facing side and the articulating component bone-facing side, and prior to heating at least the bone anchoring component joint-facing side and the articulating component bone-facing side to the bonding temperature:

assembling the articulating component and the bone anchoring component such that the paste is sandwiched between the bone anchoring component joint-facing side and the articulating component bone-facing side; and

pressing the bone anchoring component joint-facing side and the articulating component bone-facing side together.

10. The method of claim 9, wherein heating at least the bone anchoring component joint-facing side and the articulating component bone-facing side to the bonding temperature comprises, with the bone anchoring component joint-facing side and the articulating component bone-facing side pressed together, heating at least the bone anchoring component joint-facing side and the articulating component bone-facing side to 500°

C. to debind the gelatin and/or glycerin and melt the Titanium-based nanoparticles.

11. A method for manufacturing a prosthesis for replacing an articular surface on a bone, the method comprising:

casting metals comprising at least Cobalt and Chromium to form an articulating component comprising;

an articulating component joint-facing side comprising an articular surface; and

an articulating component bone-facing side comprising a bone-facing shape; and

direct metal laser sintering Titanium to form a bone anchoring component comprising;

a bone anchoring component joint-facing side comprising a joint-facing shape that is complementary to the bone-facing shape; and

a bone anchoring component bone-facing side comprising a bone engagement surface having a porous structure with pores selected to facilitate in-growth of the bone into the pores;

applying a paste containing flake-shaped Titanium-based nanoparticles produced via ball milling to at least one of the bone anchoring component joint-facing side and the articulating component bone-facing side;

assembling the articulating component and the bone anchoring component such that the paste is sandwiched between the bone anchoring component joint-facing side and the articulating component bone-facing side; and

heating the paste to a bonding temperature sufficient to commence melting of the Titanium-based nanoparticles to secure the bone anchoring component joint-facing side to the articulating component bone-facing side.

12. The method of claim 11, further comprising:

anodizing the bone anchoring component to form a surface layer of Titanium Dioxide nanotubes on the bone anchoring component joint-facing side; and

after assembling the articulating component and the bone anchoring component, pressing the articulating component and the bone anchoring component together;

wherein;

the paste further comprises a gelatin and/or a glycerin; and

heating the paste to the bonding temperature comprises, with the articulating component and the bone anchoring component pressed together, heating at least the bone anchoring component joint-facing side and the articulating component to a temperature sufficient to debind the gelatin and/or glycerin, melt the Titanium-based nanoparticles, and changing at least a portion of the surface layer of Titanium Dioxide nanotubes to anatase.