Patient-specific manufacturing of porous metal prostheses

• US 9,662,214 B2
• Filed: 05/04/2012
• Issued: 05/30/2017
• Est. Priority Date: 05/06/2011
• Status: Active Grant

• Current Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Original Assignee: Zimmer Incorporated (Zimmer Biomet Holdings, Inc.)
• Inventors: Li, Jia, Cron, Scott V., Bassett, Jeffrey, Willis, Edward M
• Primary Examiner(s): Yuan, Dah-Wei D
• Assistant Examiner(s): Bowman, Andrew
• Application Number:
  US13/464,069
• Publication Number:
  US 20120310364A1
• Time in Patent Office: 1,852 Days
• Field of Search: 623 1711
• CPC Class Codes: A61F 2/2803 for mandibular reconstruction temporo-mandibular joints A61F2/3099; bone plates for the jaw A61B17/8071
• CPC Class Codes: A61F 2/30767 Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
• CPC Class Codes: A61F 2/30942 for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2/44 for the spine, e.g. vertebrae, spinal discs
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/3093 for promoting ingrowth of bone tissue
• 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 2002/3096 trimmed or cut to a customised size
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: A61F 2002/30963 using templates, e.g. grid charts
• CPC Class Codes: A61F 2002/30985 using three dimensional printing [3DP]
• CPC Class Codes: A61F 2310/00011 Metals or alloys
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C23C 16/06 : characterised by the deposition of metallic material
• CPC Class Codes: C23C 16/44 : characterised by the method of coating C23C16/04 takes precedence
• CPC Class Codes: F04C 2270/041 : Controlled or regulated

Abstract

A patient-specific porous metal prosthesis and a method for manufacturing the same are provided. The orthopedic prosthesis may be metallic to provide adequate strength and stability. Also, the orthopedic prosthesis may be porous to promote bone ingrowth.

Claims

1. A method of manufacturing a custom, patient-specific orthopaedic prosthesis for a patient'"'"'s damaged bone, the method comprising the steps of:

obtaining a patient-specific mold designed from image data of the patient'"'"'s damaged bone;

inserting a porous substrate into a negative space defined by the patient-specific mold, the porous substrate including a plurality of struts that define pores of the porous substrate, wherein the porous substrate has a first shape being slightly larger than the negative space defined by the patient-specific mold;

shaping the porous substrate by compressing the slightly larger porous substrate within the negative space defined by the patient-specific mold, wherein compressing the porous substrate with the patient-specific mold permanently deforms, breaks, or crushes a portion of the plurality of struts of the porous substrate to reshape the porous substrate; and

after the shaping step, coating struts of the porous substrate with a biocompatible metal.

2. The method of claim 1, further comprising the step of

obtaining image data of the patient'"'"'s damaged bone;

designing a prosthesis model from image data of the patient'"'"'s damaged bone, the prosthesis model being representative of the custom, patient-specific orthopaedic prosthesis.

3. The method of claim 2, wherein the negative space of the patient-specific mold is smaller in scale than the prosthesis model to account for a size increase that occurs during the coating step.

4. The method of claim 1, wherein the porous substrate comprises reticulated vitreous carbon.

5. The method of claim 1, wherein the shaping step comprises forcing the patient-specific mold into a closed position around the porous substrate.

6. The method of claim 1, wherein the coating step comprises performing a chemical vapor deposition process to infiltrate and coat an interior region of the porous substrate.

7. The method of claim 1 wherein the patient-specific mold is manufactured by a first party and the shaping step is carried out by a second party.

8. The method of claim 1, wherein the shaping step comprises shaping the porous substrate from the first shape to a second shape.

9. The method of claim 8, wherein the porous substrate comprises reticulated vitreous carbon.

10. The method of claim 8, wherein the second shape differs from the first shape.

11. The method of claim 10, wherein the negative space defined by the patient-specific mold comprises a shape that corresponds to the second shape of the porous substrate.

12. The method of claim 10, wherein the porous substrate is more readily shapeable before the coating step than after the coating step.

13. The method of claim 10, wherein the first shape is a regular shape and the second shape is an irregular shape.

14. The method of claim 10, wherein the first shape is a symmetrical shape and the second shape is an asymmetrical shape.

15. The method of claim 10, wherein at least a portion of the pores decrease in size during the shaping step.

16. The method of claim 10, wherein at least a portion of the pores decrease in size during the coating step.

17. The method of claim 10, wherein the second shape is smaller than the first shape.

18. The method of claim 17, wherein the porous substrate includes friable or brittle struts that are readily crushed or broken during said compressing, and wherein some of the struts are removed from the porous substrate and discarded before the coating step.