Custom bioimplantable article
First Claim
1. A method of making a custom, bioimplantable article comprising the steps of:
- creating a data file that defines a three-dimensional shape of at least a portion of the custom, bioimplantable article;
providing the data file to a rapid prototyping machine;
fabricating a mold representative of at least a portion of the custom, bioimplantable article with the rapid prototyping machine as defined by the data file;
positioning the mold relative to an existing, non-custom representation of a bioimplantable article to define a hybrid component;
creating a ceramic shell around the hybrid component;
removing the existing, non-custom representation of a bioimplantable article from the ceramic shell;
introducing molten metal into the ceramic shell;
allowing the molten metal to harden; and
removing the ceramic shell from the hardened metal.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of making a custom, bioimplantable article, such as a joint prosthesis component, is provided using computer aided design, rapid prototyping, and investment casting techniques. The method includes the creation of a data file, using computer aided design (CAD) techniques, that defines a negative or a shell of a portion of a bioimplantable article that is custom configured for a specific arthroplasty patient. The data file for the shell of the custom portion of the bioimplantable article is accessed by a rapid prototyping machine, such as a three-dimensional printer, to create a mold that corresponds to the shell. The mold, generally a heat-resistant ceramic, is positioned relative to an existing, non-custom representation of a bioimplantable article to define a hybrid component. A heat-resistant shell is formed around the hybrid component and the non-custom representation of a bioimplantable article is removed from the shell using heat. Molten metal is introduced into the ceramic shell and allowed to harden. The ceramic shell is removed and the resultant custom, bioimplantable article is subjected to standard surface finishing procedures as required.
311 Citations
19 Claims
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1. A method of making a custom, bioimplantable article comprising the steps of:
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creating a data file that defines a three-dimensional shape of at least a portion of the custom, bioimplantable article; providing the data file to a rapid prototyping machine; fabricating a mold representative of at least a portion of the custom, bioimplantable article with the rapid prototyping machine as defined by the data file; positioning the mold relative to an existing, non-custom representation of a bioimplantable article to define a hybrid component; creating a ceramic shell around the hybrid component; removing the existing, non-custom representation of a bioimplantable article from the ceramic shell; introducing molten metal into the ceramic shell; allowing the molten metal to harden; and removing the ceramic shell from the hardened metal. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of making a custom joint prosthesis component comprising the steps of:
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creating a data file with a computer aided design program that defines a three-dimensional shape of at least a portion of the custom joint prosthesis component; providing a rapid prototyping apparatus; providing the data file to the rapid prototyping machine; fabricating a mold for at least a portion of the custom joint prosthesis component with the rapid prototyping machine by forming a ceramic shell as defined by the data file; providing a plurality of non-custom representations of a biomedical article; selecting one of the non-custom representations of the biomedical article; juxtaposing the selected, non-custom representation of a biomedical article with the mold; attaching the selected, non-custom representation of a biomedical article to the mold with refractory cement to define a hybrid component; creating a ceramic shell around the hybrid component; removing the selected, non-custom representation of a biomedical article from the ceramic shell by heating the selected, non-custom representation of a biomedical article to a molten state; and allowing the molten article to flow out of the ceramic shell; introducing molten metal into the ceramic shell; allowing the molten metal to harden; and removing the ceramic shell from the hardened metal. - View Dependent Claims (14, 15, 16, 17, 18)
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19. A method of making a custom orthopedic implant comprising the steps of:
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creating a custom orthopedic implant model using computer aided design techniques; creating a shell of the orthopedic implant model using computer aided design techniques; forming a ceramic mold representative of the shell of the orthopedic implant model with a rapid prototyping machine; providing a heat destructible implant model; juxtaposing the heat destructible implant model with the ceramic mold to provide a hybrid component; creating a ceramic shell around the hybrid component; applying heat to the ceramic shell to destroy the heat destructible implant model; introducing molten metal into the ceramic shell; allowing the molten metal to harden; and removing the ceramic shell from the hardened metal.
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Specification