US 12,005,616 B2
Implantable medical device with varied composition and porosity, and method for forming same
Jeffery A. Farris, Berne, IN (US); Kevin Lee Brown, Fort Wayne, IN (US); Douglas B. Snell, Overland Park, KS (US); Ryan K. Roeder, Granger, IN (US); and Mark G. Messman, Larwill, IN (US)
Assigned to HAPPE SPINE LLC, Grand Rapids, MI (US)
Filed by HAPPE SPINE LLC, Grand Rapids, MI (US)
Filed on Jul. 22, 2022, as Appl. No. 17/870,911.
Application 17/870,911 is a continuation of application No. 17/473,385, filed on Sep. 13, 2021, granted, now 11,426,904.
Application 17/870,911 is a continuation of application No. PCT/US2021/050074, filed on Sep. 13, 2021.
Claims priority of provisional application 63/077,308, filed on Sep. 11, 2020.
Prior Publication US 2023/0089343 A1, Mar. 23, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. A61L 27/48 (2006.01); A61F 2/28 (2006.01); A61F 2/30 (2006.01); A61L 27/56 (2006.01); B29C 43/00 (2006.01); B29C 43/14 (2006.01); B29K 101/12 (2006.01); B29L 31/00 (2006.01)
CPC B29C 43/006 (2013.01) [A61F 2/28 (2013.01); A61F 2/30942 (2013.01); A61F 2/30965 (2013.01); B29C 43/003 (2013.01); A61F 2002/30957 (2013.01); B29C 2793/009 (2013.01); B29K 2101/12 (2013.01); B29L 2031/7532 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method for forming a unitary article, comprising the following steps:
i. provide at least two powder blends, each of the at least two powder blends being selected from the group consisting of at least one polymer powder, at least one polymer powder with at least one porogen powder, at least one polymer powder with at least one inorganic particle powder, and at least one polymer powder with at least one porogen powder and at least one inorganic particle powder, such that the at least two powder blends differ from one another in terms of content of the polymer powder, content of the porogen powder, content of the inorganic particle powder, or a combination thereof;
ii. dispense each of the at least two powder blends into at least one mold;
iii. compact each of the at least two powder blends into two or more preforms;
iv. machine each of the two or more preforms into two or more parts with complementary mating surfaces;
v. assemble the two or more parts with complementary mating surfaces to form an article assembly;
vi. compression mold the article assembly to form a unitary article;
vii. optionally form additional features in the unitary article; and
viii. leach porogen from the unitary article.