Implantable articles with as-cast macrotextured surface regions and method of manufacturing the same

• US 5,687,788 A
• Filed: 06/01/1995
• Issued: 11/18/1997
• Est. Priority Date: 02/18/1994
• Status: Expired due to Fees

• Current Assignee: Johnson and Johnson Professional Inc (Johnson & Johnson)
• Original Assignee: Johnson and Johnson Professional Inc (Johnson & Johnson)
• Inventors: Flynn, Timothy M., Caldarise, Salvatore, LaSalle, David L., Manginelli, Richard P.
• Primary Examiner(s): Lin, Kuang Y.
• Application Number:
  US08/457,227
• Time in Patent Office: 901 Days
• Field of Search: 164/4.1, 164/6, 164/525, 164/526, 164/527, 164/528, 164/529, 164/456
• US Class Current: 164/456
• CPC Class Codes: A61F 2/28 Bones joints A61F2/30
• CPC Class Codes: A61F 2/30771 applied in original prostheses, e.g. holes or grooves
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2/367 Proximal or metaphyseal parts of shafts trochanteric devices connected to said proximal parts A61F2/30739
• CPC Class Codes: A61F 2/3676 Distal or diaphyseal parts of shafts
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/389 Tibial components A61F2/3868 takes precedence
• CPC Class Codes: A61F 2002/30011 differing in porosity
• CPC Class Codes: A61F 2002/30322 differing in surface structures
• CPC Class Codes: A61F 2002/30682 Means for preventing migration of particles released by the joint, e.g. wear debris or cement particles
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30957 using a positive or a negative model, e.g. moulds
• CPC Class Codes: A61F 2002/30968 Sintering
• CPC Class Codes: A61F 2250/0023 differing in porosity
• CPC Class Codes: A61F 2250/0026 differing in surface structures
• CPC Class Codes: A61F 2310/00023 Titanium or titanium-based alloys, e.g. Ti-Ni alloys
• CPC Class Codes: A61F 2310/00029 Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: B22C 7/02 Lost patterns
• CPC Class Codes: B22C 9/04 Use of lost patterns
• CPC Class Codes: B29B 2009/125 Micropellets, microgranules, microparticles
• CPC Class Codes: B29B 9/12 : characterised by structure or composition
• CPC Class Codes: B29B 9/16 : Auxiliary treatment of granules
• CPC Class Codes: B29C 33/3842 : Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 64/165 : using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29L 2031/7532 : Artificial members, protheses
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 40/20 : Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y10S 623/901 : Method of manufacturing prosthetic device
• CPC Class Codes: Y10S 623/923 : Bone

Abstract

An implantable article having on at least a portion of its exterior surface an integral, as-cast macrotextured surface with macropores having undercut edge profiles. A complex macrotextured surface is provided by forming a casting mold so that the mold has complementary macrotextured surface features formed by three-dimensional printing techniques, and casting a molten metal within or in contact with the casting mold to form the implantable article. In a hybrid process, one or more printed surface mold plates are attached by hand, or in a wax molding process, to a simpler wax preform, and an investment is made in which the plates are incorporated into the investment mold. A casting is then made, with each preform yielding one cast article, and the incorporated plate forming the desired surface macrotexture on a region of the east article. Pore size, porosity and pore shape may be varied across the surface, or varied with depth, to independently enhance different mechanical and physiological factors at the bone-prosthesis interface.

Claims

1. A method of making a bone prosthesis, comprising the steps of

a) providing a predetermined, computer controlled scan actuation pattern suitable to yield a casting mold having formed therein a macrotextured surface having macropores with undercut edge profiles in selected regions thereof;

b) depositing a layer of a ceramic-forming powder material in a confined region;

c) applying a binder material to the ceramic-forming powder material in selected regions of the layer, according to the predetermined scan actuation pattern, to solidify the ceramic-forming powder material in the selected regions;

d) repeating steps (b) and (c) a predetermined number of times to deposit successive layers of ceramic-forming powder, with variations in regions to which binder material is applied such that a solidified portion of each layer is bonded to a preceding layer, to form a casting mold that defines a negative of the bone prosthesis, at least a portion of the casting mold having a textured surface including macropores with undercut edge profiles corresponding to the variations of said regions;

e) removing loose ceramic-forming powder material from the casting mold;

f) casting a material in contact with the casting mold and hardening the material to form a bone prosthesis; and

g) removing the bone prosthesis from the casting mold, whereby the bone prosthesis has an as-cast macro textured surface characterized by macropores with undercut edge profiles on at least a portion of its exterior.

2. The method of claim 1 wherein the powder material is a ceramic forming material selected from the group consisting of alumina, beryllia, silica, silicon carbide, zirconia and mixtures thereof.

3. The method of claim 1 wherein the binder material comprises an organic or inorganic binder material selected from the group consisting of aqueous colloidal silica, alcohol-based colloidal silica, cellulosic resins, butyral resins, polycarbosilazane, silicate-based materials, alcohol based binders, and alkyd-based binders.

4. The method of claim 1 where the binder material comprises aqueous colloidal silica.

5. The method of claim 1 further comprising the step of removing non-bonded ceramic-forming powder and firing the casting mold to yield a ceramic material.

6. The method of claim 1 wherein the molten metal is a metal alloy.

7. The method of claim 1 further wherein the step of removing the bone prosthesis from the casting mold includes destroying the casting mold.

8. A method of making a bone prosthesis comprising the steps of:

providing a predetermined, computer controlled scan actuation pattern suitable to yield a casting mold having formed therein a macrotextured surface having macropores with undercut edge profiles in selected regions thereof;

applying a three-dimensional printing process to form a green casting mold by successive applications of a binder material to a ceramic forming powder according to the predetermined scan actuation pattern, to bond at least some of the powder together into a solid body forming said green casting mold, at least a portion of the green casting mold having a macroporous textured surface including macropores with undercut edge profiles;

removing non-bonded powder material from the green casting mold;

firing the green casting mold to yield a ceramic casting mold;

casting a molten metal against the ceramic casting mold and allowing the molten metal to harden in contact with the casting mold to form the bone prosthesis, at least a portion of the bone prosthesis thereby having an as-cast macrotextured surface including macropores with undercut edge profiles; and

separating the bone prosthesis from the casting mold.

9. The method of claim 8, wherein the green casting mold comprises a plate, and the process further comprises the steps of

attaching the plate to a wax form;

forming an investment about the plate and form; and

firing the plate and investment to yield said ceramic casting mold.