ORTHOPEDIC IMPLANTS AND METHODS OF MANUFACTURING ORTHOPEDIC IMPLANTS

• US 20150045903A1
• Filed: 08/08/2014
• Published: 02/12/2015
• Est. Priority Date: 08/09/2013
• Status: Active Grant

• Current Assignee: Kapstone Medical, LLC
• Original Assignee: David J. Neal
• Inventors: Neal, David J.
• Granted Patent: US 10,016,811 B2
• Time in Patent Office: Days
• US Class Current: 623/21.18
• CPC Class Codes: A61F 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30118 concentric circles
• CPC Class Codes: A61F 2002/30131 horseshoe- or crescent- or C-shaped or U-shaped
• CPC Class Codes: A61F 2002/30133 kidney-shaped or bean-shaped
• CPC Class Codes: A61F 2002/30153 rectangular
• CPC Class Codes: A61F 2002/30156 triangular
• CPC Class Codes: A61F 2002/30158 trapezoidal
• CPC Class Codes: A61F 2002/30187 D-shaped or half-disc-shaped
• CPC Class Codes: A61F 2002/30224 cylindrical
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: A61F 2002/3097 using laser
• CPC Class Codes: A61F 2002/4207 Talar components
• CPC Class Codes: A61F 2002/4223 Implants for correcting a flat foot
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• 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 5/106 Tube or ring forms
• CPC Class Codes: B22F 7/004 comprising at least one non-porous part
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: B23K 15/0006 : specially adapted for particular articles
• CPC Class Codes: B23K 15/0086 : welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 2103/05 : Stainless steel
• CPC Class Codes: B23K 2103/08 : Non-ferrous metals or alloys
• CPC Class Codes: B23K 2103/14 : Titanium or alloys thereof
• CPC Class Codes: B23K 2103/15 : Magnesium 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 26/0006 : taking account of the properties of the material involved B23K26/32, B23K26/40 take precedence
• CPC Class Codes: B23K 26/32 : taking account of the properties of the material involved
• CPC Class Codes: B23K 26/342 : Build-up welding
• CPC Class Codes: B23K 26/354 : by melting
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A method of manufacturing an orthopedic implant is provided. The method includes creating a 3D model of an orthopedic implant having a solid portion and a porous portion and selectively adjusting a physical property of at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography of the 3D model. The entire implant is then additively manufactured based on the 3D model.

Claims

1. A method of manufacturing an orthopedic implant comprising:

creating a 3D model of a part having a solid portion and a porous portion;

selectively adjusting a physical property of at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography of the 3D model; and

additively manufacturing the entire part based on the 3D model.

2. The method of claim 1, wherein the step of additively manufacturing includes direct metal laser sintering the entire part, selective laser sintering the entire part or electron beam melting the entire part.

3. The method of claim 1, wherein the step of selectively adjusting the physical property of at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography the 3D model is adjusted based on an intended implantation position of the implant in bone.

4. An orthopedic implant comprising a solid portion and a porous portion each formed by additive manufacturing the entire implant based on a 3D model of the implant having a physical property selectively adjusted based upon a position the implant is to be implanted in bone.

5. The orthopedic implant of claim 4, wherein the physical property is at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography.

6. The orthopedic implant of claim 4, wherein the implant is a wedge implant having:

an aperture extending through the wedge implant;

a first circumferential solid portion of the implant adjacent the aperture;

a second circumferential solid portion of the implant spaced from the first circumferential solid portion;

a first porous portion of the implant between the first and second circumferential solid portions; and

a second porous portion circumscribing the second circumferential solid portion.

7. The orthopedic implant of claim 6, wherein the first porous portion has a higher density of porous structures at a position proximal to the aperture than a density of porous structures at a position distal to the aperture.

8. The orthopedic implant of claim 6, wherein the wedge implant has a cross-sectional profile that is D-shaped, donut-shaped, teardrop-shaped, triangular shaped, rectangular shaped, frustum-shaped, trapezoidal shaped, or sickle-shaped.

9. The orthopedic implant of claim 4, wherein the implant comprises:

a cylindrical solid body; and

a porous coating surrounding the cylindrical solid body.

10. The orthopedic implant of claim 9, wherein the implant is a talar navicular implant, an ankle block, an ankle subtalar block, an ankle rod, or a talar navicular cuneiform rod.

11. The orthopedic implant of claim 10, wherein the talar-navicular implant further comprises an aperture extending through the solid body transverse to a longitudinal axis of the cylindrical solid body.

12. The orthopedic implant of claim 10, wherein the ankle rod further comprises a fastener at one end of the ankle rod.

13. The orthopedic implant of claim 12, wherein the ankle rod further comprises an aperture extending through the solid body transverse to a longitudinal axis of the cylindrical solid body.

14. The orthopedic implant of claim 4, wherein the implant is an rod implant having:

a cylindrical solid body;

fastener at a first end of the rod implant; and

a first porous coating region covering the fastener, a second porous coating region covering a second end of the rod implant, and a third porous coating region covering a portion of the cylindrical solid body spaced from the first and second coating regions.

15. The orthopedic implant of claim 14, wherein the rod implant further comprises first and second apertures extending through the solid body transverse to a longitudinal axis of the cylindrical solid body.

17. The orthopedic implant of claim 13, wherein the implant has a cross-sectional profile that is D-shaped, circular shaped, teardrop-shaped, triangular shaped, rectangular shaped, frustum-shaped, trapezoidal shaped, or sickle-shaped.

18. The orthopedic implant of claim 13, wherein a surface area percentage of at least one of the first solid portion, second solid portion, first porous portion, and second porous portion is modified based upon a position the implant is to be implanted in bone.

16. An orthopedic implant comprising:

a first solid portion;

a second solid portion spaced from and circumscribing the first solid portion;

a first porous portion between the first and second solid portions; and

a second porous portion circumscribing the second solid portion,

wherein the implant is formed completely by additive manufacturing based on a 3D model of the implant.