Laser-produced porous surface
First Claim
1. A method of producing a three-dimensional porous tissue ingrowth structure comprising:
- depositing a first layer of a metal powder onto a substrate;
scanning a laser beam having a negative beam overlap at least once over at least a portion of the first layer of metal powder to remelt at least a portion of the metal powder in order to create at least two solid portions separated from one another so as to control porosity;
depositing a second layer of metal powder onto the first layer; and
repeating the laser scanning steps for each successive layer until a desired height is reached.
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Accused Products
Abstract
A method of fabricating a porous or partially porous three-dimensional metal article for use as a tissue ingrowth surface on a prosthesis. The porous article is formed using direct laser remelting in a cross section of a layer of metallic powder on a build platform without fusing thereto. The power, speed, spot size and beam overlap of the scanning laser is coordinated so that a predetermined porosity of the metallic powder can be achieved. Laser factors also vary depending from the thickness of the powder layer, type of metallic powder and size and size distribution of the powder particles. Successive depositing and remelting of individual layers are repeated until the article is fully formed by a layer-by-layer fashion. In an additional embodiment, a first layer of metallic powder may be deposited on a solid base or core and fused thereto.
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Citations
17 Claims
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1. A method of producing a three-dimensional porous tissue ingrowth structure comprising:
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depositing a first layer of a metal powder onto a substrate; scanning a laser beam having a negative beam overlap at least once over at least a portion of the first layer of metal powder to remelt at least a portion of the metal powder in order to create at least two solid portions separated from one another so as to control porosity; depositing a second layer of metal powder onto the first layer; and repeating the laser scanning steps for each successive layer until a desired height is reached. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of producing a three-dimensional porous tissue ingrowth structure comprising:
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depositing a first layer of metal powder onto a substrate; scanning a laser beam having a power and a diameter with a speed between approximately 100 mms−
1 to 260 mms−
1 and a beam overlap less than zero over the metal powder to remelt the metal powder in order to create at least two solid lines so as to control porosity, the negative beam overlap allowing for a non-solid space between the two solid lines; anddepositing at least one additional layer of the metal powder onto the first layer and repeating the laser scanning steps for each successive layer. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of producing a three-dimensional porous tissue ingrowth structure comprising:
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providing a substrate made of a metal selected from selected from the group consisting of titanium, titanium alloys, stainless steel, cobalt chrome alloys, tantalum and niobium;
depositing a first layer of a metal powder onto the substrate, the metal powder selected from the group consisting of titanium, titanium alloys, stainless steel, cobalt chrome alloys, tantalum and niobium;scanning a laser beam having a negative beam overlap at least once over at least a portion of the first layer of metal powder to remelt at least a portion of the metal powder in order to create at least two solid portions separated from one another so as to control porosity; depositing a second layer of metal powder onto the first layer; and repeating the laser scanning steps for each successive layer until a desired height is reached, wherein during the step of repeating the laser scanning steps, at least one laser scan is carried out angled relative to another laser scan in order to develop an interconnecting or non-interconnecting porosity.
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Specification