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

Kyocera Medical Technologies Inc

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 a surgical implant device comprising a metallic implant body and a porous layer formed on the metallic implant body. The porous layer has an external layer that is microtextured and approximates a scanned three-dimensional spongy bone surface, and comprises an irregular lattice of intersecting struts with randomized struct intersection locations and strut cross-sectional diameters.

A plurality of needle structures have an external surface that is microtextured and protrude from the porous layer opposite the metallic implant body, and the needle structures are integrally formed by an additive manufacturing process. At least some of the needle structures are longer and traverse through the porous layer and are coupled directly to the metallic implant body, while at least some are shorter and are coupled directly only to the porous layer and not to the metallic implant body.

At least some of the longer needle structures are coupled directly to the metallic implant body and to intersecting lattice struts on the implant body. The plurality of needle structures increase the coefficient of friction of an exterior surface of the surgical implant device, and the porous layer and microtextured needle structures are produced using additive manufacturing with software-defined melt, structure, and needle volumes and patterns based on a scanned spongy bone surface.

Claims Coverage

The independent claim covers one surgical implant device concept with a porous microtextured irregular lattice and microtextured needle structures that are additively manufactured and differentially coupled, including a requirement that the needle structures increase the coefficient of friction. Dependent claims further define coupling to intersecting struts, needle orientation, randomized needle arrangement, software-defined volume/pattern workflow, and an exemplary needle surface density.

Overall, the claim set focuses on a metallic implant body with an additively manufactured microtextured irregular lattice porous layer approximating a scanned spongy bone surface, and microtextured needle structures protruding from the porous layer. The needle structures are integrally formed by additive manufacturing, traverse and couple to the metallic implant body for at least some needles, are coupled only to the porous layer for at least some shorter needles, and increase the coefficient of friction of the device exterior surface; dependent claims further specify coupling to intersecting struts, substantially normal and random needle placement, software-defined volume/pattern design, and a needle density of about 0.3 needles/mm2.

Stated Advantages

Documented Applications

No documented applications found