US 11,944,549 B2
3D printed monoblock orthopaedic surgical implant with customized patient-specific augment
Ryan C. Keefer, Warsaw, IN (US); Bernice A. Gatrell, Warsaw, IN (US); Andrew M. Hudson, Warsaw, IN (US); Christel M. Wagner, Warsaw, IN (US); Catherine Santis, Warsaw, IN (US); Daniel N. Huff, Warsaw, IN (US); and Paul B. Sade, Sr., Warsaw, IN (US)
Assigned to DEPUY SYNTHES PRODUCTS, INC., Raynham, MA (US)
Filed by DEPUY SYNTHES PRODUCTS, INC., Raynham, MA (US)
Filed on Mar. 31, 2021, as Appl. No. 17/219,554.
Prior Publication US 2022/0313443 A1, Oct. 6, 2022
Int. Cl. A61F 2/34 (2006.01); A61F 2/30 (2006.01)
CPC A61F 2/34 (2013.01) [A61F 2/30942 (2013.01); A61F 2002/30957 (2013.01); A61F 2002/30985 (2013.01); A61F 2002/3432 (2013.01); A61F 2002/345 (2013.01); A61F 2002/348 (2013.01); A61F 2310/00011 (2013.01); A61F 2310/00179 (2013.01)] 6 Claims
OG exemplary drawing
 
1. A monoblock acetabular shell component, the shell component comprising:
a solid substrate;
a porous outer layer coupled to the solid substrate, wherein the porous outer layer has a porosity greater than the solid substrate;
a porous inner layer coupled to the solid substrate, wherein the porous inner layer has a porosity greater than the solid substrate; and
an inner bearing coupled to the porous inner layer, wherein the inner bearing comprises a bearing surface and wherein the bearing surface defines a cavity sized to receive an orthopaedic implant component;
wherein the solid substrate or the porous outer layer includes a patient-specific adjunct integrally formed therewith and extending outwardly from the porous outer layer, wherein the patient-specific adjunct comprises an outer surface, and wherein the outer surface defines a customized patient-specific negative contour shaped to conform to a positive contour of a patient's bone; and
wherein each of the solid substrate, the porous outer layer, the porous inner layer, and the inner bearing comprises a ceramic material.