RETICULATED MESH ARRAYS AND DISSIMILAR ARRAY MONOLITHS BY ADDITIVE LAYERED MANUFACTURING USING ELECTRON AND LASER BEAM MELTING

• US 20100291401A1
• Filed: 05/14/2010
• Published: 11/18/2010
• Est. Priority Date: 05/15/2009
• Status: Active Grant

• Current Assignee: Board of Regents of the University of Texas System (University of Texas System)
• Original Assignee: Board of Regents of the University of Texas System (University of Texas System)
• Inventors: Murr, Lawrence, Medina, Frank, Gaytan, Sara, Wicker, Ryan
• Granted Patent: US 8,828,311 B2
• Time in Patent Office: Days
• US Class Current: 428/593
• CPC Class Codes: A61F 2/0063 Implantable repair or support meshes, e.g. hernia meshes
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/38 to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 10/66 by mechanical means
• CPC Class Codes: B22F 10/68 Cleaning or washing
• CPC Class Codes: B22F 3/115 by spraying molten metal, i.e. spray sintering, spray casting
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 2103/14 Titanium or alloys thereof
• CPC Class Codes: B23K 2103/26 Alloys of Nickel and Cobalt and Chromium
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/32 taking account of the properties of the material involved
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y10T 428/12028 Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
• CPC Class Codes: Y10T 428/12042 Porous component
• CPC Class Codes: Y10T 428/1234 Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]
• CPC Class Codes: Y10T 428/12347 : Plural layers discontinuously bonded [e.g., spot-weld, mechanical fastener, etc.]

Abstract

Compositions and methods for making a three dimensional structure comprising: designing a three-dimensional structure; melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or laser beam is described herein. The position where the metal is melted into the structure is formed along a layer of metal powder, wherein the location and intensity of the beam that strikes the metal layer is based on the three-dimensional structure and is controlled and directed by a processor. The instant invention comprises a novel dry state sonication step for removing metal powder that is not melted from the three dimensional structure.

Claims

1. A method of making a three dimensional structure comprising:

designing a three-dimensional structure;

melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or a laser beam, wherein the position where the metal is melted into the structure is formed along a layer of metal powder, wherein a location and an intensity of the beam striking the metal layer is based on the three-dimensional structure and is controlled and directed by a processor; and

removing the metal powder from the three-dimensional structure that is not melted.

2. The method of claim 1, wherein the step of removing the metal powder further comprises the steps of:

contacting the metal powder that is not melted with one or more ultrasonic devices; and

removing the metal powder that is not melted by sonication using the one or more ultrasonic devices, wherein the sonication is a dry sonication.

3. The method of claim 2, wherein the one or mole ultrasonic devices are selected from the group consisting of resonant probes, ultrasonic welders or related high frequency sound transmission devices.

4. The method of claim 2, wherein the ultrasonic device is a resonant probe.

5. The method of claim 4, wherein the resonant probe is operated at frequencies ranging from 20 to 80 kHz.

6. The method of claim 2, wherein a frequency of operation of the one or more ultrasonic device is dependent on a shape, a density, and a geometry of the three-dimensional structure.

7. The method of claim 1, wherein the three dimensional structure comprises at least a portion that is a reticulated mesh array.

8. The method of claim 1, wherein the beam melts metal powder layers using electron or laser beams.

9. The method of claim 1, wherein the metal powder comprises Ti-6Al-4V.

10. The method of claim 1, wherein the metal powder comprises Co-26Cr-6Mo-0.2C.

11. The method of claim 1, wherein the three dimensional structure comprises at least one of a porous coating, a thin porous bead coating, a sintered mesh array, a thermal-spray coating, and a metallic foam on a medical device.

12. The method of claim 1, further comprising the steps of obtaining three-dimensional coordinates for a shape for tissue replacement, calculating the shape of a three-dimensional implant based on the three-dimensional coordinates of the shape for tissue replacement, and forming the three-dimensional implant.

13. The method of claim 1, further comprising the steps of obtaining three-dimensional coordinates for a shape for tissue replacement, calculating the shape of a three-dimensional implant based on the three-dimensional coordinates of the shape for tissue replacement, and selecting one or more metal powders to form the three-dimensional implant based on at least one of weight, mechanical strength, porosity, geometry and biocompatibility.

14. The method of claim 1, further comprising the step of adding one or more biocompatible polymers to the three dimensional structure.

15. The method of claim 1, further comprising the step of adding one or more cellular growth factors.

16. The method of claim 1, wherein the three dimensional structure comprises orthopedic implants, femoral stems, tibial stems, femoral rods, and combinations and modifications thereof.

17. A three dimensional structure made by the method of claim 1.

18. A method of making a biologically compatible, three dimensional, mesh array comprising:

designing a three-dimensional mesh array structure comprising lattice elements;

melting the three-dimensional mesh array structure from two or more layers of a biocompatible metal powder with a high energy electron beam, wherein a position where the metal is melted into the structure is formed along a layer of metal powder, wherein a location and an intensity of the beam striking the metal layer is based on the three-dimensional structure and is controlled and directed by a processor; and

removing metal powder from the three-dimensional structure that is not melted.

19. The method of claim 18, wherein the step of removing the metal powder further comprises the steps of:

contacting the metal powder that is not melted with one or more ultrasonic devices; and

removing the metal powder that is not melted by sonication using the one or more ultrasonic devices, wherein the sonication is a dry state sonication.

20. The method of claim 19, wherein the one or mole ultrasonic devices are selected from the group consisting of resonant probes, ultrasonic welders or related high frequency sound transmission devices.

21. The method of claim 19, wherein the ultrasonic device is a resonant probe.

22. The method of claim 21, wherein the resonant probe is operated at frequencies ranging from 20 to 80 kHz.

23. The method of claim 19, wherein a frequency of operation of the one or more ultrasonic device is dependent on a shape, a density, and a geometry of the three dimensional reticulated mesh array.

24. The method of claim 18, wherein the beam melts metal powder layers using electron or laser beams.

25. The method of claim 18, wherein the metal powder comprises Ti-6Al-4V.

26. The method of claim 18, wherein the metal powder comprises Co-26Cr-6Mo-0.2C.

27. The method of claim 18, wherein the three dimensional structure comprises at least one of a porous coating, a thin, porous bead coating, a sintered mesh arrays, a thermal-spray coating, and a metallic foam on a medical device.

28. The method of claim 18, further comprising the steps of obtaining three-dimensional coordinates for a shape for tissue replacement, calculating the shape of a three-dimensional implant based on the three-dimensional coordinates of the shape for tissue replacement, and forming the three-dimensional implant.

29. The method of claim 18, further comprising the steps of obtaining three-dimensional coordinates for a shape for tissue replacement, calculating the shape of a three-dimensional implant based on the three-dimensional coordinates of the shape for tissue replacement, and selecting one or more metal powders to form the three-dimensional implant based on at least one of weight, mechanical strength, porosity, geometry and biocompatibility.

30. The method of claim 18, further comprising the step of adding one or more biocompatible polymers to the three dimensional structure.

31. The method of claim 18, further comprising the step of adding one or more cellular growth factors.

32. The method of claim 18, comprising the optional step of annealing and polishing the biologically compatible, three dimensional, reticulated mesh array.

33. A biologically compatible, three dimensional, mesh array made by the method of claim 18.