LAYER BY LAYER MANUFACTURING OF A STENT

• US 20100070022A1
• Filed: 09/11/2009
• Published: 03/18/2010
• Est. Priority Date: 09/12/2008
• Status: Abandoned Application

• Current Assignee: Boston Scientific Scimed (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Scimed (Boston Scientific Corporation)
• Inventors: Kuehling, Michael
• Application Number:
  US12/558,153
• Publication Number:
  US 20100070022A1
• Time in Patent Office: Days
• US Class Current: 623/1.160
• CPC Class Codes: A61F 2/82 Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents stent-grafts for tubular structures of the body other than blood vessels A61F2/04; stent-grafts for blood vessels A61F2/07; instruments specially adapted for placement or removal of stents or stent-grafts A61F2/95; for closing wounds, or holding wounds closed A61B17/04 - A61B17/115; dilators A61M29/00
• CPC Class Codes: A61F 2/915 with bands having a meander structure, adjacent bands being connected to each other
• CPC Class Codes: A61F 2002/91541 Adjacent bands are arranged out of phase
• CPC Class Codes: A61F 2002/91575 connected peak to trough
• CPC Class Codes: A61F 2210/0076 multilayered, e.g. laminated structures
• CPC Class Codes: A61F 2230/0054 V-shaped
• CPC Class Codes: A61F 2250/0023 differing in porosity
• CPC Class Codes: A61F 2250/0031 made from both resorbable and non-resorbable prosthetic parts, e.g. adjacent parts
• CPC Class Codes: A61F 2250/0068 the pharmaceutical product being in a reservoir
• CPC Class Codes: A61L 31/10 Macromolecular materials
• CPC Class Codes: A61L 31/146 Porous materials, e.g. foams or sponges
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49888 Subsequently coating

Abstract

A stent is provided which has a relatively less porous support structure that includes a first set of consolidated particles and at least one relatively more porous reservoir that includes a second set of consolidated particles that differ in composition from the first set of consolidated particles.

Claims

1. A stent, comprising:

a relatively less porous support structure that includes a first set of consolidated particles and at least one relatively more porous reservoir that includes a second set of consolidated particles that differ in composition from the first set of consolidated particles.

2. The stent of claim 1 further comprising one or more therapeutic agents located in pores of the porous reservoir.

3. The stent of claim 2 wherein the one or more therapeutic agents are provided in the pores of the porous reservoir such that the porous reservoir regulates transport of chemical species between the reservoir and an exterior of the stent upon implantation or insertion of the stent into a subject.

4. The stent of claim 1 wherein the support structure comprises a plurality of struts and the porous reservoir is located in one of the struts.

5. The stent of claim 1 wherein the first set of consolidated particles are metal or ceramic particles.

6. The stent of claim 1 wherein the second set of consolidated particles includes biodisintegrable particles.

7. The stent of claim 1 wherein the porous reservoirs are exposed to at least a luminal surface of the strut.

8. The stent of claim 1 further comprising at least one porous seal located over an exposed surface of the reservoir to further regulate transport of the chemical species between the reservoir and the exterior of the stent.

9. The stent of claim 2 wherein said therapeutic agent is selected from one or more of the group consisting of anti-thrombotic agents, anti-proliferative agents, anti-inflammatory agents, anti-restenotic agents, anti-migratory agents, agents affecting extracellular matrix production and organization, antineoplastic agents, anti-mitotic agents, anesthetic agents, anti-coagulants, vascular cell growth promoters, vascular cell growth inhibitors, cholesterol-lowering agents, vasodilating agents, TGF-β

elevating agents, and agents that interfere with endogenous vasoactive mechanisms.

10. A method of manufacturing a stent, comprising:

dividing a three-dimensional pattern of a stent into a series of layers, at least a plurality of the layers including a relatively less porous region and a relatively more porous region;

sequentially printing each of the layers, one on top of another, from a plurality of different types of particles; and

sequentially compacting and sintering each of the layers such that the more porous regions of the plurality of layers collectively form a support structure and the less porous regions of the plurality of layers collectively form at least one porous reservoir located in the support structure.

11. The method of claim 10 wherein the plurality of different particles include a first particulate composition used to print the relatively more porous regions and a second particulate composition used to print the relatively less porous regions, wherein the first particulate composition is different from the second particulate composition.

12. The method of claim 11 wherein at least one of the first and second particulate compositions comprises metallic particles.

13. The method of claim 11 wherein the second particulate composition comprises biodisintegrable particles.

14. The method of claim 10 wherein the support structure comprises a series of interconnected struts, said porous reservoir being located in one of the struts.

15. The method of claim 10 wherein the porous reservoir is exposed to at least a luminal or abluminal surface of the strut.

16. The method of claim 10 further comprising introducing one or more therapeutic agents into the reservoir.

17. The method of claim 16 further comprising applying a porous seal over the reservoir to regulate transport of the one or more therapeutic agents between the reservoir and an exterior of the stent.

18. The method of claim 10 further comprising rolling the compacted and sintered layers into a tubular shape.

19. The method of claim 10 wherein each of the layers extends along a plane perpendicular to a longitudinal axis of the stent.

20. The method of claim 10 wherein sequentially printing each of the layers includes electrostatically attracting the particles to a layer pattern formed on a photoreceptor.