SYSTEM AND METHOD FOR PRODUCING A THREE-DIMENSIONAL BODY COMPRISING BONE OR TISSUE-COMPATIBLE MATERIAL

• US 20050154483A1
• Filed: 06/28/2004
• Published: 07/14/2005
• Est. Priority Date: 12/28/2001
• Status: Active Grant

• Current Assignee: Nobel Biocare AB (Danaher Corporation)
• Original Assignee: Nobel Biocare AB (Danaher Corporation)
• Inventors: Berggren, Carina
• Granted Patent: US 7,079,914 B2
• Time in Patent Office: Days
• US Class Current: 700/119
• CPC Class Codes: A61C 13/0003 Making bridge-work, inlays, implants or the like
• CPC Class Codes: A61C 13/0004 Computer-assisted sizing or machining of dental prostheses
• CPC Class Codes: A61C 13/0019 using three dimensional printing
• CPC Class Codes: A61C 5/77 Methods or devices for making crowns
• CPC Class Codes: C23C 4/12 characterised by the method of spraying
• CPC Class Codes: C23C 4/185 Separation of the coating from the substrate

Abstract

A system useful in producing a three-dimensional body comprising bone or tissue-compatible material includes a detection and analysis site which identifies and simulates a portion of a body in connection with an implantation situation. A production device produces a model responsive to the simulation information. A flame-spraying apparatus provides the bone-compatible and/or tissue-compatible material in a powder form through a nozzle. Relative movement between the nozzle and a support member supporting the model or die is controlled to apply one or more layers of the bone-compatible material to the model. A method includes using a computer to identify and simulate a body in connection with a given implantation situation, and producing a model or die accordingly the bone or tissue-compatible material is flame-sprayed in a powder form. Movements of a nozzle and/or a supporting member are controlled so as to effect a desired surface characteristic on the three-dimensional body.

Claims

1. A system useful in producing a three-dimensional body comprising bone-compatible and/or tissue-compatible material, the system comprising:

identification and simulation means for identifying and simulating at least a portion of a body in connection with an implantation situation;

a production device which produces a model or die responsive to identification and simulation information provided by the identification and simulation means;

a high-velocity injection-molding apparatus which provides the bone-compatible and/or tissue-compatible material in a powder form through a nozzle; and

controlling means for controlling relative movement between the nozzle and a support member supporting the model or die,

wherein the high-velocity injection-molding apparatus is arranged to apply layers of the bone-compatible and/or tissue-compatible material to the model or die via the nozzle during simultaneous movement control of at least one of the nozzle and the supporting member.

2. A system useful in producing a three-dimensional body comprising bone-compatible and/or tissue-compatible material, the system comprising:

a detection and analysis site comprising identification and simulation means for identifying and simulating at least a portion of a body in connection with an implantation situation;

a production device which produces a model or die responsive to identification and simulation information provided by the identification and simulation means;

a flame-spraying apparatus which provides the bone-compatible and/or tissue-compatible material in a powder form through a nozzle; and

controlling means for controlling relative movement between the nozzle and a support member supporting the model or die,

wherein the flame-spraying apparatus is arranged to apply a layer of the bone-compatible and/or tissue-compatible material to the model or die via the nozzle during simultaneous movement control of at least one of the nozzle and the supporting member.

3. The system of claim 2, wherein the bone-compatible and/or tissue-compatible material comprises titanium.

4. The system of claim 2, wherein the bone-compatible and/or tissue-compatible material comprises gold.

5. The system of claim 2, wherein the bone-compatible and/or tissue-compatible material comprises steel.

6. The system of claim 2, wherein the identification and simulation means comprises a computer processor.

7. The system of claim 2, further comprising control means for controlling a surface configuration of the three-dimensional body.

8. The system of claim 2, wherein variations in a wall thickness and an outer configuration of the bone-compatible and/or tissue-compatible material covering the model or die are controlled by means for controlling one or both of the flame-spray apparatus and the relative movement between the nozzle and the model or die.

9. The system of claim 2, wherein plural thin layers of the bone-compatible and/or tissue-compatible material are applied to the model or die from the nozzle, wherein the plural thin layers form a framework.

10. The system of claim 9, wherein the framework on the three-dimensional body is suitable for being separated from the model or die after the plural layers have hardened.

11. The system of claim 3, wherein the titanium comprises titanium powder having a purity of about 99.99%.

12. The system of claim 3, wherein the titanium comprises titanium powder having a relatively small particle size of about 325 mesh.

13. The system of claim 2, further comprising plural detection and analysis sites separated from each other,

wherein the production device produces multiple models responsive to associated identification and simulation information provided by respective ones of the plural detection and analysis sites.

14. The system of claim 2, further comprising a communication network which couples the identification and simulation information to the detection and analysis site.

15. A three-dimensional body produced by the system of claim 2, wherein the three-dimensional body is suitable for use in an implantation process directly without further after-treatment.

16. A method for producing a three-dimensional body comprising bone-compatible and/or tissue-compatible material, the method comprising:

using a computer to identify and simulate a body in connection with a given implantation situation;

producing a model or die responsive to the identification and simulation of the body;

flame-spraying the bone-compatible and/or tissue-compatible material in a powder form through a nozzle;

applying one or more coating layers of the bone-compatible and/or tissue-compatible material to the model or die via the nozzle;

simultaneously, with said applying one or more coating layers, controlling movement of the nozzle and/or a supporting member of the body so as to effect a desired surface characteristic on the three-dimensional body.

17. The method of claim 16, wherein the bone-compatible and/or tissue-compatible material comprises titanium powder.

18. The method of claim 16, further comprising:

hardening the one or more coating layers of the bone-compatible and/or tissue-compatible material;

removing the three-dimensional body from the model or die; and

using the three-dimensional body directly in the given implantation situation without further after-treatment.

19. A three-dimensional body produced by the method of claim 16.

20. A device useful in an implantation situation, the device comprising:

a three-dimensional body comprising bone-compatible and/or tissue-compatible material applied in layers,

wherein the material is suitable for application by a flame spraying process.

21. The device of claim 20, wherein the layers have sufficient strength to be self-supporting.

22. The device of claim 20, wherein the material comprises titanium.