US 12,220,863 B2
Medical devices and methods for forming medical devices containing a build plate
Zachary John Beers Post, Memphis, TN (US); Vivek Pawar, Germantown, TN (US); Dawn Ryan McLean, Eads, TN (US); Roger Ryan Dees, Jr., Drummods, TN (US); Brad Dacus, Memphis, TN (US); and Sean Haddock, Germantown, TN (US)
Assigned to SMITH & NEPHEW, INC., Memphis, TN (US); SMITH & NEPHEW ORTHOPAEDICS AG SMITH, Zug (CH); and NEPHEW ASIA PACIFIC PTE. LIMITED, Singapore (SG)
Appl. No. 17/602,657
Filed by Smith & Nephew, Inc., Memphis, TN (US); Smith & Nephew Orthopaedics AG, Zug (CH); and Smith & Nephew Asia Pacific Pte. Limited, Singapore (SG)
PCT Filed Apr. 8, 2020, PCT No. PCT/US2020/027261
§ 371(c)(1), (2) Date Oct. 8, 2021,
PCT Pub. No. WO2020/210353, PCT Pub. Date Oct. 15, 2020.
Claims priority of provisional application 62/832,683, filed on Apr. 11, 2019.
Prior Publication US 2022/0168106 A1, Jun. 2, 2022
Int. Cl. A61F 2/30 (2006.01); B22F 10/28 (2021.01); B29C 64/153 (2017.01); B29C 64/245 (2017.01); B32B 3/30 (2006.01); B32B 5/14 (2006.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); B29L 31/00 (2006.01); B32B 5/16 (2006.01)
CPC B29C 64/153 (2017.08) [A61F 2/30771 (2013.01); A61F 2/3094 (2013.01); B29C 64/245 (2017.08); B32B 3/30 (2013.01); B32B 5/145 (2013.01); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12); A61F 2002/30321 (2013.01); A61F 2002/30322 (2013.01); A61F 2002/30962 (2013.01); A61F 2002/30968 (2013.01); A61F 2002/3097 (2013.01); B22F 10/28 (2021.01); B29L 2031/7532 (2013.01); B32B 5/16 (2013.01); B32B 2535/00 (2013.01); Y10T 428/24479 (2015.01); Y10T 428/24521 (2015.01); Y10T 428/24529 (2015.01); Y10T 428/24537 (2015.01); Y10T 428/24579 (2015.01); Y10T 428/24612 (2015.01); Y10T 428/2462 (2015.01); Y10T 428/24942 (2015.01)] 20 Claims
OG exemplary drawing
 
1. A medical device, comprising:
a build plate having a plurality of peaks and a plurality of indentations, the plurality of peaks and the plurality of indentations together defining a surface roughness of an exterior surface of the build plate; and
a first layer formed atop the exterior surface of the build plate, the first layer comprising a plurality of powder structures disposed over the plurality of peaks and the plurality of indentations, wherein an average peak distance between adjacent peaks of the plurality of peaks is less than an average width dimension of at least a portion of the plurality of powder structures;
wherein each peak of the plurality of peaks comprises a tip;
wherein the plurality of powder structures are configured to melt to form a melt pool during a thermal treatment;
wherein the tips of at least some of the plurality of peaks are configured to melt during the thermal treatment and mix together with the melt pool, solidifying to form the first layer as a consolidated first layer.