Laser based metal deposition (LBMD) of implant structures

• US 7,666,522 B2
• Filed: 05/10/2006
• Issued: 02/23/2010
• Est. Priority Date: 12/03/2003
• Status: Expired due to Fees

• Current Assignee: IMDS Corporation
• Original Assignee: IMDS Corporation
• Inventors: Justin, Daniel F., Fallin, T. Wade, Gabbita, Durga Janaki Ram, Stucker, Brent E.
• Primary Examiner(s): McNeil; Jennifer
• Assistant Examiner(s): Savage; Jason L
• Application Number:
  US11/432,426
• Publication Number:
  US 20070202351A1
• Time in Patent Office: 1,385 Days
• Field of Search: None
• US Class Current: 428/615
• CPC Class Codes: A61C 8/0012 characterised by the material or composition, e.g. ceramics, surface layer, metal alloy use of specific materials A61K6/00
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/3099 for temporo-mandibular [TM, TMJ] joints endoprostheses for mandibular reconstruction A61F2/2803
• CPC Class Codes: A61F 2/36 Femoral heads ; Femoral endoprostheses
• CPC Class Codes: A61F 2/3662 Femoral shafts
• CPC Class Codes: A61F 2/38 for elbows or knees
• CPC Class Codes: A61F 2/3804 for elbows
• CPC Class Codes: A61F 2/3859 Femoral components
• CPC Class Codes: A61F 2/40 for shoulders
• 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 2/4261 for wrists
• CPC Class Codes: A61F 2002/30451 soldered or brazed or welded
• CPC Class Codes: A61F 2002/30604 modular
• CPC Class Codes: A61F 2002/30733 Inserts placed into an endoprosthetic cavity, e.g. for modifying a material property
• CPC Class Codes: A61F 2002/30805 Recesses of comparatively large area with respect to their low depth
• CPC Class Codes: A61F 2002/30878 with non-sharp protrusions, for instance contacting the bone for anchoring, e.g. keels, pegs, pins, posts, shanks, stems, struts
• CPC Class Codes: A61F 2002/30922 Hardened surfaces
• CPC Class Codes: A61F 2002/30929 having at least two superposed coatings
• CPC Class Codes: A61F 2002/30934 Special articulating surfaces
• CPC Class Codes: A61F 2002/30967 : Diffusion bonding
• CPC Class Codes: A61F 2002/3097 : using laser
• CPC Class Codes: A61F 2002/30971 : Laminates, i.e. layered products
• CPC Class Codes: A61F 2002/3611 : Heads or epiphyseal parts of femur
• CPC Class Codes: A61F 2002/3625 : Necks
• CPC Class Codes: A61F 2002/3652 : Connections of necks to shafts
• CPC Class Codes: A61F 2002/4253 : for thumbs
• CPC Class Codes: A61F 2220/0058 : soldered or brazed or welded
• CPC Class Codes: A61F 2310/00017 : Iron- or Fe-based alloys, e.g. stainless steel
• 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: A61F 2310/00131 : Tantalum or Ta-based alloys
• CPC Class Codes: A61F 2310/00293 : containing a phosphorus-containing compound, e.g. apatite
• CPC Class Codes: A61F 2310/00407 : Coating made of titanium or of Ti-based alloys
• CPC Class Codes: A61F 2310/00413 : Coating made of cobalt or of Co-based alloys
• CPC Class Codes: A61L 27/04 : Metals or alloys
• CPC Class Codes: A61L 27/306 : Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: A61L 27/56 : Porous materials, e.g. foams or sponges
• CPC Class Codes: B22F 10/25 : Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/32 : of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 12/41 : characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/53 : Nozzles
• CPC Class Codes: B22F 12/55 : Two or more means for feeding material
• 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 2103/18 : Dissimilar materials
• 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 2103/52 : Ceramics
• CPC Class Codes: B23K 26/32 : taking account of the properties of the material involved
• CPC Class Codes: B23K 26/324 : involving non-metallic parts
• CPC Class Codes: B23K 26/34 : Laser welding for purposes other than joining
• CPC Class Codes: B23K 35/0244 : Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/0261 : Rods, electrodes, wires
• CPC Class Codes: B23K 35/325 : Ti as the principal constituent
• CPC Class Codes: B23K 35/327 : comprising refractory compounds, e.g. carbides
• CPC Class Codes: C22C 14/00 : Alloys based on titanium
• CPC Class Codes: C23C 24/10 : with intermediate formation of a liquid phase in the layer
• CPC Class Codes: C23C 26/02 : applying molten material to the substrate
• CPC Class Codes: C23C 28/021 : including at least one metal alloy layer
• CPC Class Codes: C23C 28/023 : only coatings of metal elements only
• CPC Class Codes: C23C 28/028 : Including graded layers in composition or in physical properties, e.g. density, porosity, grain size
• CPC Class Codes: C23C 28/321 : with at least one metal alloy layer
• CPC Class Codes: C23C 28/322 : only coatings of metal elements only
• CPC Class Codes: C23C 28/34 : including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
• CPC Class Codes: C23C 28/341 : with at least one carbide layer
• CPC Class Codes: C23C 28/347 : with layers adapted for cutting tools or wear applications
• CPC Class Codes: C23C 28/36 : including layers graded in composition or physical properties
• CPC Class Codes: C23C 4/12 : characterised by the method of spraying
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y10T 428/12458 : having composition, density, or hardness gradient
• CPC Class Codes: Y10T 428/12493 : Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
• CPC Class Codes: Y10T 428/12576 : Boride, carbide or nitride component
• CPC Class Codes: Y10T 428/12806 : Refractory [Group IVB, VB, or VIB] metal-base component
• CPC Class Codes: Y10T 428/12812 : Diverse refractory group metal-base components: alternative to or next to each other
• CPC Class Codes: Y10T 428/12847 : Cr-base component
• CPC Class Codes: Y10T 428/12931 : Co-, Fe-, or Ni-base components, alternative to each other

Abstract

A method is provided for depositing a hard wear resistant surface onto a porous or non-porous base material of a medical implant. The wear resistant surface of the medical implant device may be formed by a Laser Based Metal Deposition (LBMD) method such as Laser Engineered Net Shaping (LENS). The wear resistant surface may include a blend of multiple different biocompatible materials. Further, functionally graded layers of biocompatible materials may be used to form the wear resistant surface. Usage of a porous material for the base may promote bone ingrowth to allow the implant to fuse strongly with the bone of a host patient. The hard wear resistant surface provides device longevity, particularly when applied to bearing surfaces such as artificial joint bearing surfaces or a dental implant bearing surfaces.

Claims

1. A medical implant device comprising:

a metal base structure; and

an articulating bearing material formed onto said metal base structure by Laser Based Metal Deposition (LBMD) in an inert gas atmosphere;

wherein said articulating bearing material comprises functionally graded layers of biocompatible materials;

wherein the articulating bearing material comprises a blend of biocompatible materials.

2. A device as in claim 1, wherein said articulating bearing material articulates with a second medical implant device.

3. A device as in claim 1, wherein said metal base structure comprises a base shaped to be secured to a body part of a patient.

4. A device as in claim 1, wherein said metal base structure comprises a material selected from the group consisting of:

Titanium, Cobalt-Chrome, Tantalum, Platinum, Zirconium, Niobium, stainless steel, and alloys thereof.

5. A device as in claim 1, wherein said articulating bearing material comprises a first material selected from the group consisting of:

Titanium, Titanium alloys, Cobalt-Chrome, Tantalum, Platinum, Zirconium, Niobium, stainless steel, and any alloys thereof.

6. A device as in claim 5, wherein said articulating bearing material further comprises a second material which is dissimilar from said first material, wherein said second material is selected from the group consisting of:

Titanium, Titanium Carbide, other carbides, borides, nitrides, and intermetallics.

7. A device as in claim 1, wherein said articulating bearing material has a hardness greater than a hardness of said metal base structure.

8. A method for constructing a medical implant device, the method comprising:

forming a structure from a base metal; and

depositing an articulating bearing material onto a surface of the base metal using Laser Based Metal Deposition (LBMD) in an inert gas atmosphere,

wherein said articulating bearing material comprises functionally graded layers of biocompatible material;

wherein said articulating bearing material comprises a blend of biocompatible materials.

9. A method as in claim 8, wherein said articulating bearing material articulates with a second medical implant device.

10. A method as in claim 8, wherein said structure comprises a base shaped to be secured to a body part of a patient.

11. A method as in claim 8, wherein said articulating bearing material comprises a first material selected from the group consisting of:

Titanium, Titanium alloys, Cobalt-Chrome, Tantalum, Platinum, Zirconium, Niobium, stainless steel, and any alloys thereof.

12. A method as in claim 11, wherein said articulating bearing material further comprises a second material which is dissimilar from said first material, wherein said second material is selected from the group consisting of:

Titanium, Titanium Carbide, other carbides, borides, nitrides, and intermetallics.

13. A method as in claim 8, wherein said articulating bearing material has a hardness greater than a hardness of said structure.

14. A method as in claim 8, wherein depositing said articulating bearing material onto said surface comprises applying said articulating bearing material as a powder and heating said powder with a laser.

15. A method as in claim 8, wherein depositing said articulating bearing material onto said surface comprises applying said articulating bearing material as a foil and heating said foil with a laser.

16. A method as in claim 8, wherein depositing said articulating bearing material onto said surface comprises applying said articulating bearing material as a wire and heating said wire with a laser.

17. A method as in claim 8, wherein depositing said articulating bearing material onto said surface comprises heating said articulating bearing material with a high power Nd YAG laser.

18. The method of claim 8, wherein depositing said articulating bearing material onto said surface comprises using Laser Engineered Net Shaping (LENS).

19. The method of claim 8, wherein depositing said articulating bearing material onto said surface comprises using an electron beam metal deposition process.

20. The method of claim 8, wherein depositing said articulating bearing material onto said surface comprises using a plasma energy source.

21. The method of claim 8, wherein depositing said articulating bearing material onto said surface comprises using a welding based cladding process.

22. A medical implant device comprising:

a metal base structure; and

an articulating bearing material formed onto said metal base structure by Laser Based Metal Deposition (LBMD) in an inert gas atmosphere;

wherein said articulating bearing material comprises functionally graded layers of biocompatible materials.

23. A device as in claim 22, wherein said articulating bearing material articulates with a second medical implant device.

24. A device as in claim 22, wherein said metal base structure comprises a base shaped to be secured to a body part of a patient.

25. A device as in claim 22, wherein said metal base structure comprises a material selected from the group consisting of:

Titanium, Cobalt-Chrome, Tantalum, Platinum, Zirconium, Niobium, stainless steel, and alloys thereof.

26. A device as in claim 22, wherein said articulating bearing material comprises a first material selected from the group consisting of:

Titanium, Titanium alloys, Cobalt-Chrome, Tantalum, Platinum, Zirconium, Niobium, stainless steel, and any alloys thereof.

27. A device as in claim 26, wherein a concentration of said first material in each functionally graded layer ranges from 10 to 90 percent.

28. A device as in claim 26, wherein said articulating bearing material further comprises a second material which is dissimilar from said first material, wherein said second material is selected from the group consisting of:

Titanium, Titanium Carbide, other carbides, borides, nitrides, and intermetallics.

29. A device as in claim 28, wherein a concentration of said second material in each functionally graded layer ranges from 10 to 90 percent.

30. A device as in claim 22, wherein said articulating bearing material has a hardness greater than a hardness of the metal base structure.

31. A device as in claim 22, wherein a number of functionally graded layers of articulating bearing material ranges from one to ten.

32. A device as in claim 22, wherein a thickness of each functionally graded layer of articulating bearing material does not equal a thickness of each other functionally graded layer.

33. A method for constructing a medical implant device, the method comprising:

forming a structure from a base metal; and

depositing an articulating bearing material onto a surface of said base metal using Laser Based Metal Deposition (LBMD) in an inert gas atmosphere, wherein said articulating bearing material comprises functionally graded layers of biocompatible materials.

34. A method as in claim 33, wherein said articulating bearing material articulates with a second medical implant device.

35. A method as in claim 33, wherein said metal base structure is shaped to be secured to a body part of a patient.

36. A method as in claim 33, wherein said metal base structure comprises a material selected from the group consisting of:

Titanium, Cobalt-Chrome, Tantalum, Platinum, Zirconium, Niobium, stainless steel and alloys thereof.

37. A method as in claim 36, wherein said articulating bearing material comprises a first material selected from the group consisting of:

Titanium, Titanium alloys, Cobalt-Chrome, Tantalum, Platinum, Zirconium, Niobium, stainless steel, and any alloys thereof.

38. A method as in claim 37, wherein a concentration of said first material in each functionally graded layer ranges from 10 to 90 percent.

39. A method as in claim 37, wherein said articulating bearing material further comprises a second material which is dissimilar from said first material, wherein said second material is selected from the group consisting of:

Titanium, Titanium Carbide, other carbides, borides, nitrides, and intermetallics.

40. A method as in claim 39, wherein a concentration of said second material in each functionally graded layer ranges from 10 to 90 percent.

41. A method as in claim 33, wherein said articulating bearing material has a hardness greater than a hardness of the metal base structure.

42. A method as in claim 33, wherein depositing said articulating bearing material comprises applying said articulating bearing material in a number of functionally graded layers ranging from one to ten.

43. A method as in claim 33, wherein a thickness of each functionally graded layer of articulating bearing material deposited does not equal a thickness of each other functionally graded layer deposited.

44. A method as in claim 33, wherein depositing said articulating bearing material onto said surface comprises applying said articulating bearing material as a powder and heating said powder with a laser.

45. A method as in claim 33, wherein depositing said articulating bearing material onto said surface comprises applying said articulating bearing material as a foil and heating said foil with a laser.

46. A method as in claim 33, wherein depositing said articulating bearing material onto said surface comprises applying said articulating bearing material as a wire and heating said wire with a laser.

47. A method as in claim 33, wherein depositing said articulating bearing material onto said surface comprises heating said articulating bearing material with a high power Nd YAG laser.

48. The method of claim 33, wherein depositing said articulating bearing material onto said surface comprises using Laser Engineered Net Shaping (LENS).

49. The method of claim 33, wherein depositing said articulating bearing material onto said surface comprises using an electron beam metal deposition process.

50. The method of claim 33, wherein depositing said articulating bearing material onto said surface comprises using a plasma energy source.

51. The method of claim 33, wherein depositing said articulating bearing material onto said surface comprises using a welding based cladding process.