Surgical implant devices incorporating porous surfaces and associated method of manufacture
Inventors
STEINMANN, John C. • RUCKER, Scott • RASMUSSEN, Tim • STEINMANN, John P. • Cawley, Trace • Ross, Thomas • RIOS, Ernesto • OLCESE, Andrew
Assignees
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Publication Number
US-11304811-B2
Publication Date
2022-04-19
Expiration Date
Abstract
A surgical implant device, including: an implant body; a porous layer disposed adjacent to the implant body, wherein the porous layer includes a lattice of intersecting struts; and a plurality of needle structures protruding from the porous layer opposite the implant body, wherein at least some of the plurality of needle structures traverse the porous layer and are anchored to the implant body. The plurality of needle structures that traverse the porous layer and are anchored to the implant body are coupled to one or more intersecting struts of the lattice. Optionally, some of the plurality of needle structures are spaced apart from the implant body and are anchored only to the porous layer. Preferably, one or more of the implant body, the porous layer, and the plurality of needle structures are formed by an additive manufacturing technique.
Core Innovation
The invention relates to surgical implant device manufacturing in which a metallic implant body is provided and a porous layer is formed on the metallic implant body. The porous layer has an external surface that is microtextured and approximates a scanned three-dimensional spongy bone surface, and the porous layer comprises an irregular lattice of intersecting struts having randomized strut intersection locations and strut cross-sectional diameters.
A plurality of needle structures is integrally formed with an external surface that is microtextured and protruding from the porous layer opposite the metallic implant body by an additive manufacturing process. At least some of the plurality of needle structures are longer, traverse through the porous layer, and are coupled directly to the metallic implant body, while at least some of the plurality of needle structures are shorter and are coupled directly only to the porous layer and not to the metallic implant body.
The plurality of needle structures is configured so that the plurality of needle structures increase the coefficient of friction of an exterior surface of the surgical implant device. One independent claim additionally requires using a software application to define melt volume, structure volume, and needle volume, and to formulate lattice pattern and needle pattern for additive manufacturing.
Claims Coverage
The document includes two independent claims (clm-00001 and clm-00009). Both claims share the same core inventive theme: manufacturing a surgical implant device by forming a microtextured irregular-lattice porous layer approximating a scanned spongy bone surface and additively forming microtextured needle structures protruding from that porous layer, including longer needles coupled to the metallic implant body and shorter needles coupled only to the porous layer, with the needle structures increasing the coefficient of friction.
Microtextured irregular lattice porous layer approximating scanned spongy bone
forming a porous layer with an external surface that is microtextured and approximates a scanned three-dimensional spongy bone surface on the metallic implant body, wherein the porous layer comprises an irregular lattice of intersecting struts having randomized strut intersection locations and strut cross-sectional diameters
Integrally additively formed microtextured needle structures protruding from porous layer
integrally forming a plurality of needle structures having an external surface that is microtextured with and protruding from the porous layer opposite the metallic implant body by an additive manufacturing process
Long and short needles with different coupling to metallic implant body and porous layer
wherein at least some of the plurality of needle structures are longer and traverse through the porous layer and are coupled directly to the metallic implant body and at least some of the plurality of needle structures are shorter relative to the longer needle structures and are coupled directly only to the porous layer and not to the metallic implant body
Needles increase coefficient of friction of exterior surface
wherein the plurality of needle structures increase the coefficient of friction of an exterior surface of the surgical implant device
Software-defined volumes and patterns for lattice and needles
using a software application, defining a melt volume corresponding to a volume occupied by a metallic implant body; using the software application, defining a structure volume corresponding to a volume occupied by a porous layer; using the software application, defining a needle volume corresponding to a volume occupied by a plurality of needle structures; using the software application, formulating a lattice pattern within the structure volume; using the software application, formulating a needle pattern within the needle volume; and additively manufacturing at least the porous layer using the lattice pattern and the plurality of needle structures using the needle pattern
Across the independent claims, the main inventive coverage is the combination of a microtextured porous layer approximating a scanned spongy bone surface using an irregular lattice with randomized strut intersection locations and diameters, additively forming microtextured needle structures protruding from the porous layer, including longer needles traversing the porous layer and coupled to the metallic implant body and shorter needles coupled only to the porous layer, and configuring the needle structures to increase the coefficient of friction of the exterior surface, with one independent claim additionally requiring software application definition of melt, structure, and needle volumes and lattice and needle patterns.
Stated Advantages
The plurality of needle structures increase the coefficient of friction of an exterior surface of the surgical implant device.
Documented Applications
Not explicitly described in patent.
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