US 11,701,146 B2
Surgical implant and methods of additive manufacturing
Patrick Melton, Seattle, WA (US); and Michael Prosser, Mount Pleasant, SC (US)
Assigned to K2M, Inc., Leesburg, VA (US)
Filed by K2M, Inc., Leesburg, VA (US)
Filed on Apr. 9, 2021, as Appl. No. 17/226,453.
Application 17/226,453 is a continuation of application No. 15/643,603, filed on Jul. 7, 2017, granted, now 11,006,981.
Prior Publication US 2021/0290273 A1, Sep. 23, 2021
Int. Cl. A61B 17/70 (2006.01); A61B 34/10 (2016.01); A61F 2/30 (2006.01); A61F 2/44 (2006.01); A61B 17/86 (2006.01); B29C 64/393 (2017.01); B29C 64/153 (2017.01); B33Y 50/02 (2015.01); B33Y 70/00 (2020.01); B22F 7/06 (2006.01); A61B 17/80 (2006.01); B22F 10/00 (2021.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); A61B 17/00 (2006.01); B29L 31/00 (2006.01); B22F 10/14 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/68 (2021.01); B22F 12/00 (2021.01); B22F 10/40 (2021.01); B22F 10/80 (2021.01); B22F 10/60 (2021.01); B22F 10/64 (2021.01); B22F 10/66 (2021.01)
CPC A61B 17/7035 (2013.01) [A61B 17/7032 (2013.01); A61B 17/7037 (2013.01); A61B 17/7049 (2013.01); A61B 17/80 (2013.01); A61B 17/86 (2013.01); A61B 34/10 (2016.02); A61F 2/30942 (2013.01); A61F 2/442 (2013.01); A61F 2/4455 (2013.01); B22F 7/06 (2013.01); B22F 10/00 (2021.01); B29C 64/153 (2017.08); B29C 64/393 (2017.08); B33Y 50/02 (2014.12); B33Y 70/00 (2014.12); A61B 2017/00526 (2013.01); A61B 2034/108 (2016.02); A61F 2002/3085 (2013.01); A61F 2002/30578 (2013.01); A61F 2002/30787 (2013.01); A61F 2002/30952 (2013.01); A61F 2002/30971 (2013.01); A61F 2002/30985 (2013.01); B22F 10/14 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/40 (2021.01); B22F 10/60 (2021.01); B22F 10/64 (2021.01); B22F 10/66 (2021.01); B22F 10/68 (2021.01); B22F 10/80 (2021.01); B22F 12/38 (2021.01); B29L 2031/753 (2013.01); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12)] 20 Claims
OG exemplary drawing
 
1. A method of manufacturing a surgical implant comprising:
forming a first component of the surgical implant by:
depositing a first quantity of material;
fusing the first quantity of material to form a first fused layer;
depositing a second quantity of material over the first fused layer; and
fusing the second quantity of material to form a second fused layer;
forming a second component of the surgical implant by:
depositing a third quantity of material over a portion of a surface of the first component prior to depositing and fusing a final quantity of material for forming a final fused layer of the first component such that the portion of the surface of the first component supports the third quantity of material;
fusing the third quantity of material to form a third fused layer;
depositing a fourth quantity of material over the third fused layer; and
fusing the fourth quantity of material to form a fourth fused layer;
wherein the first component and the second component are fully assembled upon completion of the formation of the first and second components of the surgical implant.