System and method of manufacturing a medical implant
Inventors
Reith, Todd • Linder, Eric • Heskett, Ryan
Assignees
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Publication Number
US-11597148-B2
Publication Date
2023-03-07
Expiration Date
Abstract
A system and method for forming a medical implant using a printing device. The printing device includes a print head having a heated nozzle, a heated build plate for receiving the printed material thereon, and a reflective plate having an active heater. A method for forming a medical device includes extruding a printing material by contiguous deposition to form a porous object having a lattice-like structure. The medical device, such as a spinal implant, may have interconnected pores and different regions, each having a different porosity for encouraging bone growth therein. The printed medical implant may be designed to be patient-specific, customized, and printed on-demand.
Core Innovation
The disclosure describes a selectively porous customizable medical implant made by fused filament fabrication using a 3-D printer. The implant includes a continuous strand having at least a first region with a lattice structure that defines interconnected asymmetrical openings of varying shape and size, creating a first porosity, and at least a second region with a lattice structure defining interconnected asymmetrical openings of varying shape and size, creating a second porosity that differs from the first porosity by opening size. The implant further includes a plurality of layers in which each layer includes at least one of the first region or the second region, with the continuous strand progressing between layers so that a successive layer connects to a prior layer between planes in a Z-axis.
Every layer is deposited through contiguous deposition of the print material, and each layer is deposited completely prior to a next layer being deposited. The described implant structures form porous, lattice-like regions with interconnected asymmetrical openings, including selectively porous regions that have different porosity in different portions of the implant. In example structures, deposition patterns are provided for forming porous lattice geometry, including wave and zig-zag contiguous bead arrangements that provide a layered progression and interconnection between layers across the Z-axis.
The disclosure further includes spinal implant examples and surgical implant configurations using polymer materials such as polyaryl-ether-ketone (PAEK) and polymer monofilament 3-D printing processes. A porous section can be formed with a lattice structure and interconnected asymmetrical openings on top and bottom surfaces, while a non-porous section is formed of a second material distinct from the first polymer material and is connected to the porous section to form the spinal implant. The selectively porous regions and connected non-porous section are described together with deposition structures intended to facilitate bone growth, including hydroxyapatite (HA) coating extending into openings.
Claims Coverage
The document contains three independent claims. Across these independent claims, the core claimed subject matter is an additive-manufactured implant with contiguous deposition and lattice-bounded interconnected asymmetrical openings, including regionally varying porosity, and a spinal implant configuration that combines a porous polymer lattice section with a connected non-porous distinct-material section.
Selectively porous customizable implant with first and second porosities
A selectively porous customizable medical implant made by a process of fused filament fabrication using a 3-D printer, wherein a continuous strand includes at least a first region with a lattice structure defining interconnected asymmetrical openings of varying shape and size creating a first porosity, and at least a second region with a lattice structure defining interconnected asymmetrical openings of varying shape and size creating a second porosity, the first porosity having openings of a different size than the second porosity.
Contiguous deposition with complete layer deposition and Z-axis layer connections
A plurality of layers in which each layer includes at least one of the first region or the second region, the continuous strand progresses between each layer, a successive layer connects to a prior layer between planes in a Z-axis, every layer is deposited through a contiguous deposition of the print material, and each layer is deposited completely prior to a next layer being deposited.
Spinal implant with porous lattice section connected to non-porous section
A spinal implant formed by at least partially by a polymer monofilament 3-D printing process, comprising a porous section including a lattice structure of rows deposited by a continuous flow of a strand of the polymer monofilament defining a plurality of interconnected asymmetrical openings of varying shape and size, dimensions selectable for customizing the implant to a particular patient, and a non-porous section comprising a second material distinct from the first polymer material, wherein the porous and non-porous sections are connected to form the spinal implant.
Porous openings on top and bottom surfaces with contiguous deposition layers
The spinal implant where the plurality of interconnected asymmetrical openings comprises a first plurality of openings on the top surface and a second plurality of openings on the bottom surface, and the porous section has a plurality of layers formed by a contiguous deposition of the first polymer material during the 3-D printing process.
PAEK polymer surgical implant with lattice-bounded interconnected asymmetrical openings for bone growth
A polyaryl-ether-ketone (PAEK) polymer surgical implant formed by additive manufacturing comprising a plurality of layers forming at least one region of interconnected asymmetrical openings bounded by a lattice structure of rows deposited by a continuous flow of a continuous strand of PAEK material configured to facilitate bone growth therein.
Layer progression and complete deposition prior to next layer
The PAEK implant wherein every layer is formed through contiguous deposition such that the continuous strand progresses between each layer and a successive layer connects to a prior layer between planes in a Z-axis, and wherein a layer of the plurality of layers is completely deposited prior to the depositing of the PAEK material to form a next layer in the plurality of layers.
Across the independent claims, the document claims additive-manufactured implants that use contiguous deposition in layered formation such that each layer is completely deposited before the next, with layer-to-layer connection across Z-axis planes. The implants are defined by lattice structures with interconnected asymmetrical openings, including regionally different porosity and a spinal configuration combining a porous polymer lattice section with a connected non-porous distinct-material section.
Stated Advantages
Facilitate bone growth therein.
Customizing for a particular patient via selectable dimensions.
Documented Applications
Spinal implant, including configurations described as spinal implant examples such as cervical interbody cage, lumbar spine cage, and TLIF.
Cranial flap implant.
Maxillofacial implant.
Foot or ankle wedge implant.
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