Porous laser sintered articles
First Claim
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1. A laser sintered porous polymeric article comprising:
- a core having a first polymeric material, a first porosity, and a first amount of inorganic material;
an outer surface layer at least partially enveloping the core, the outer surface layer having a second polymeric material, a second porosity, and a second amount of inorganic material; and
an intermediary layer including a third polymeric material and being disposed between the outer surface layer and the core, the intermediary layer having both a porosity gradient and a compositional gradient, the porosity gradient having a range of porosities extending between the first porosity and the second porosity and the compositional gradient having a range of amounts of inorganic material extending between the first amount of inorganic material and the second amount of inorganic material,wherein the core is substantially non-porous and the outer surface layer is substantially porous,wherein the second amount of inorganic material is greater than the first amount of inorganic material, andwherein the inorganic material comprises a mixture of at least two components selected from the group consisting of a metal, metal alloy, calcium phosphate, stainless steel and glass.
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Abstract
The present invention provides selectively laser sintered porous polymeric articles and methods of making and using the same. In one embodiment, a method of the present invention comprises providing a first layer of particles of a first polymeric material, heating selected locations of the first layer to sinter particles of the first polymeric material to form a three-dimensional article, the three-dimensional article having a porosity of at least about 30 percent.
285 Citations
25 Claims
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1. A laser sintered porous polymeric article comprising:
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a core having a first polymeric material, a first porosity, and a first amount of inorganic material; an outer surface layer at least partially enveloping the core, the outer surface layer having a second polymeric material, a second porosity, and a second amount of inorganic material; and an intermediary layer including a third polymeric material and being disposed between the outer surface layer and the core, the intermediary layer having both a porosity gradient and a compositional gradient, the porosity gradient having a range of porosities extending between the first porosity and the second porosity and the compositional gradient having a range of amounts of inorganic material extending between the first amount of inorganic material and the second amount of inorganic material, wherein the core is substantially non-porous and the outer surface layer is substantially porous, wherein the second amount of inorganic material is greater than the first amount of inorganic material, and wherein the inorganic material comprises a mixture of at least two components selected from the group consisting of a metal, metal alloy, calcium phosphate, stainless steel and glass. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. An implant comprising:
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a first region having a first polymeric material, a first porosity, and a first amount of inorganic material, wherein the combination of the first porosity and the first amount of inorganic material promotes bone in-growth; a second region having a second polymeric material, a second porosity, and a second amount of inorganic material, wherein the combination of the second porosity and the second amount of inorganic material resists bone in-growth; and a third region including a third polymeric material and having both a porosity gradient and a compositional gradient, the porosity gradient having a range of porosities extending between the first porosity and the second porosity and the compositional gradient having a range of amounts of inorganic material extending between the first amount of inorganic material and the second amount of inorganic material, wherein the compositional gradient has a higher amount of inorganic material in regions adjacent to bone tissue and a lower amount of inorganic material in regions distal to bone tissue, wherein the first amount of inorganic material in the first region is higher than the second amount of inorganic material in the second region in order to promote tissue compatibility between the first region and an adjacent region of bone, wherein the second region is substantially non-porous and the first region has a higher porosity than the second region, and wherein the inorganic material comprises a mixture of at least two components selected from the group consisting of a metal, metal alloy, calcium phosphate, stainless steel, and glass. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25)
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Specification