Prosthetic Element for Bone Extremities Such as Fingers or Toes, or for Teeth, and Corresponding Production Method

• US 20150118650A1
• Filed: 04/08/2013
• Published: 04/30/2015
• Est. Priority Date: 04/06/2012
• Status: Active Grant

• Current Assignee: Limacorporate S.p.a (Enovis Corp.)
• Original Assignee: Limacorporate S.p.a (Enovis Corp.)
• Inventors: Pressacco, Michele
• Granted Patent: US 9,949,834 B2
• Time in Patent Office: Days
• US Class Current: 433/201.1
• CPC Class Codes: A61C 2008/0046 Textured surface, e.g. roughness, microstructure A61C8/0013 takes precedence
• CPC Class Codes: A61C 8/0037 Details of the shape
• CPC Class Codes: A61C 8/0075 Implant heads specially designed for receiving an upper structure if separable from the implant A61C8/005
• 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 2/3094 Designing or manufacturing processes
• CPC Class Codes: A61F 2/4225 for feet, e.g. toes
• CPC Class Codes: A61F 2/4241 for hands, e.g. fingers
• 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 2002/30649 Ball-and-socket joints
• CPC Class Codes: A61F 2002/30909 Nets
• 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: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 2003/1051 by electric discharge
• CPC Class Codes: B22F 3/1103 with particular physical characteristics
• 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

Prosthetic element for bone extremities such as fingers or toes, or teeth, comprising a trabecular part (20, 40, 120) and two end parts or stumps (12, 34, 112; 15, 39, 115).

Claims

1. Prosthetic element for small bone extremities such as the phalanges of a hand or foot, or for dental implants, comprising a coupling stump disposed at a first end of said prosthetic element, an insertion stump disposed at a second end of the prosthetic element, shaped so as to be inserted into a corresponding seating made inside the bone, an internal core having a structural function and consisting of a solid body, disposed intermediate between said stumps, and a trabecular part, suitable for bone integration, disposed so as to cover and line said internal core, wherein said trabecular part defines the external geometry of said internal core and constitutes mechanical, and structural continuity with it.

2. Prosthetic element as in claim 1, wherein said insertion stump is associated in a single body to said coupling stump by means of said internal core.

3. Prosthetic element as in claim 2, wherein said coupling stump is configured in shape and size so as to define at least a seating for the joint of at least a finger or a toe.

4. Prosthetic element as in claim 2, wherein said coupling stump is configured in shape and size to couple with a dental prosthesis.

5. Prosthetic element as in claim 4, wherein said coupling stump comprises a shaped surface with a configuration chosen between an embedded hexagon shape, an external hexagon shape and a conical surface.

6. Prosthetic element as in claim 1, wherein said trabecular part comprises pores, the size of which is comprised in a range between 100 microns and 300 microns, with an average size comprised between 230 microns and 290 microns.

7. Prosthetic element as in claim 6, wherein said trabecular part is defined by the repetition of a three-dimensional base cell the vertexes of which are not coplanar.

8. Method to make a prosthetic element for bone extremities such as fingers or toes, or for dental implants as in any claim hereinbefore, wherein it comprises a fusion step, either using a beam of electrons, or by using laser rays, to simultaneously make the stumps, the core as a solid body, and the trabecular part, to make a single body with structural and mechanical continuity, using layers of material in a powder state, causing the fusion thereof, said layers of powder having a thickness comprised between 20 microns and 70 microns.

9. Method as in claim 8, wherein said powder with which said layers are made has a particle size comprised between 25 microns and 45 microns.

10. Method as in claim 8, wherein said powder with which said layers are made has a particle size comprised between 45 microns and 100 microns.