Method for fabricating three dimensional structures
First Claim
1. A method of manufacturing a three dimensional structure having at least a first layer and a second layer, said method comprising:
- providing a substrate layer;
applying a first coating of a photoimageable material to the substrate layer;
preparing a first mask having a pattern corresponding to the first layer of the three dimensional structure to be manufactured;
exposing the first coating of the photoimageable material with an exposure source through the first mask such that the first layer of the three dimensional structure is provided;
applying a second coating of the photoimageable material subsequent to the first layer of the three dimensional structure;
preparing a second mask having a pattern corresponding to the second layer of the three dimensional structure to be manufactured;
exposing the second coating of the photoimageable material with the exposure source through the second mask such that the second layer of the three dimensional structure is provided; and
developing and removing regions of said first and second coatings that do not correspond to a layer of the three dimensional structure.
1 Assignment
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Accused Products
Abstract
A method of manufacturing a three dimensional structure. In one embodiment, such structures comprise porous structures suitable for implantation in a host. Such a structure preferably exhibits geometric properties that tend to promote vascularization in the area of the structure when implanted into a host. The method includes selectively applying and exposing layers of biocompatible photoimageable material to create layers forming a cross-linked latticework structure having the desired geometric properties. Each layer is formed on top of a prior layer, preferably before any layer is developed. In one form, the structure is manufactured in connection with an implant device and promotes vascularization that supports bioacceptance/biocompatibility of the implant device.
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Citations
70 Claims
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1. A method of manufacturing a three dimensional structure having at least a first layer and a second layer, said method comprising:
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providing a substrate layer;
applying a first coating of a photoimageable material to the substrate layer;
preparing a first mask having a pattern corresponding to the first layer of the three dimensional structure to be manufactured;
exposing the first coating of the photoimageable material with an exposure source through the first mask such that the first layer of the three dimensional structure is provided;
applying a second coating of the photoimageable material subsequent to the first layer of the three dimensional structure;
preparing a second mask having a pattern corresponding to the second layer of the three dimensional structure to be manufactured;
exposing the second coating of the photoimageable material with the exposure source through the second mask such that the second layer of the three dimensional structure is provided; and
developing and removing regions of said first and second coatings that do not correspond to a layer of the three dimensional structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42)
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43. A method of fabricating a three dimensional structure having at least a first layer and a second layer, said method comprising:
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providing a substrate layer;
applying a first coating of photoimageable material at a position subsequent to the substrate layer;
preparing a first mask having a pattern corresponding to at least a first portion of the first layer of the three dimensional structure to be fabricated;
exposing the first coating with an exposure source through the first mask such that at least a first portion of the first layer is formed;
applying a second coating of photoimageable material subsequent to the first layer;
preparing a second mask having a pattern corresponding to at least a first portion of the second layer of the three dimensional structure to be fabricated;
exposing the second coating with the exposure source through the second mask such that at least a first portion of the second layer is formed; and
applying a developing process to remove regions of the photoimageable material that do not correspond to the first and second layers. - View Dependent Claims (44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62)
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63. A method of fabricating a structure for implantation in a host, said structure including a porous three dimensional structure having at least first and second layers and being sized and shaped for producing an inflammatory foreign body response, wherein at least one of the first and second layers has a plurality of openings sized to permit fluid and inflammatory cells of the host to pass through the openings and migrate into an interior volume of the porous thee dimensional structure and sized to promote a non-flattened morphology of the inflammatory cells, and the porous three dimensional structure promoting vascularization adjacent said structure when implanted into the host, said method comprising:
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providing a microfabricated medical implant device constructed and arranged for implantation in the host, said microfabricated sensor comprising a substrate layer onto which the porous three dimensional structure can be fabricated;
applying a first coating of photoimageable material to the substrate layer;
preparing a first mask having a pattern corresponding to at least a first portion of the first layer of the three dimensional structure to be fabricated;
exposing the first coating with an exposure source through the first mask such that at least a first portion of the first layer is formed;
applying a second coating of photoimageable material subsequent to the first layer;
preparing a second mask having a pattern corresponding to at least a first portion of the second layer of the three dimensional structure to be fabricated;
exposing the second coating with the exposure source through the second mask such that at least a first portion of the second layer is formed; and
applying a developing process to remove regions of the photoimageable material that do not correspond to the first and second layers. - View Dependent Claims (64)
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65. A method of fabricating a three dimensional structure having a plurality of layers, said method comprising:
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providing a substrate;
applying a first coating of photoimageable material at a position subsequent to the substrate;
preparing a first mask having a pattern corresponding to at least a first portion of one of the plurality of layers of the three dimensional structure to be fabricated;
exposing the first coating with an exposure source through the first mask such that at least a first portion of the one of the plurality of layers is formed;
applying a second coating of photoimageable material subsequent to the first coating and after exposing the first coating with the exposure source; and
exposing the second coating with the exposure source through the first mask such that at least a second portion of the one of the plurality of layers is formed. - View Dependent Claims (66, 67, 68, 69, 70)
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Specification