Sheet based triply periodic minimal surface implants for promoting osseointegration and methods for producing same
Inventors
MILLER, Andrew Todd • Rexrode, Matthew • Kelly, Cambre • Gall, Ken
Assignees
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Publication Number
US-11026798-B1
Publication Date
2021-06-08
Expiration Date
Abstract
Provided herein are implants and methods for producing implants. In at least one embodiment, the implants include sheet-based, triply periodic, minimal surface (TPMS) portions. According to one embodiment, the TPMS portions include a gyroid architecture that provides for improved osseointegration and mechanical performance over previous implants due to novel ratios of porosity to compressive strength, among other features. In one or more embodiments, the gyroid architecture is organized into unit cells that demonstrate anisotropic mechanical performance along an insertion direction. In various embodiments, the present methods include novel selective laser melting (SLM) techniques for forming the TPMS portions of implants in a manner that reduces defect formation, thereby improving compressive performance and other implant properties.
Core Innovation
The claims describe a 3D-printed implant with a titanium sheet-based triply periodic minimal surface (TPMS) portion extending between top and bottom surfaces. One configuration specifies a titanium frame defining an interior void area integrally formed with the TPMS portion via SLM 3D printing. The TPMS portion exhibits a wall density greater than 99%, a stiffness modulus of about 3–14 GPa, a porosity of about 55–85%, and an ultimate compression strength of about 50–230 MPa.
The disclosure identifies sheet-based gyroid structures and implant embodiments integrating a TPMS with a titanium frame, including spinal-cage and osteotomy-wedge forms. It reports improved porosity-to-compressive-strength ratios compared with prior architectures and notes that anisotropic unit-cell dimensions tune directional performance. The background section and specific technical problem addressed are not explicitly described in the provided content.
Claims Coverage
The relevant claims contain two independent claims covering two inventive features directed to a 3D-printed titanium implant.
Frame-integrated titanium sheet-based TPMS implant
The 3D-printed implant comprises a top surface, a bottom surface, a titanium frame with an interior portion defining a void area, and a titanium sheet-based TPMS portion integrally formed with the frame via SLM 3D printing and extending through the void area from the top surface to the bottom surface. The TPMS portion exhibits a wall density greater than 99%, a stiffness modulus of about 3–14 GPa, a porosity of about 55–85%, and an ultimate compression strength of about 50–230 MPa.
Titanium sheet-based TPMS implant
The 3D-printed implant comprises a top surface, a bottom surface, and at least one titanium sheet-based TPMS portion extending from the top surface to the bottom surface. The TPMS portion exhibits a wall density greater than 99%, a stiffness modulus of about 3–14 GPa, a porosity of about 55–85%, and an ultimate compression strength of about 50–230 MPa.
The two independent claims cover titanium sheet-based TPMS implant configurations with defined mechanical-property ranges, with one claim additionally reciting integration with a titanium frame.
Stated Advantages
The disclosure reports improved porosity-to-compressive-strength ratios compared with prior architectures.
The disclosure reports reduced wall defects and increased measured wall density.
Documented Applications
The 3D-printed implant may take the form of a spinal cage.
The 3D-printed implant may take the form of an osteotomy wedge.
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