US 12,329,629 B2
Additive manufacturing of porous coatings separate from substrate
Gearoid Walsh, Ennis (IE); Lewis Mullen, Englewood, NJ (US); John Scanlan, Limerick (IE); and Robert W. Klein, Orangeburg, NY (US)
Assigned to Howmedica Osteonics Corp., Mahwah, NJ (US)
Filed by Howmedica Osteonics Corp., Mahwah, NJ (US)
Filed on Jun. 1, 2022, as Appl. No. 17/830,071.
Claims priority of provisional application 63/208,242, filed on Jun. 8, 2021.
Prior Publication US 2022/0387163 A1, Dec. 8, 2022
Int. Cl. A61F 2/02 (2006.01); B22F 3/00 (2021.01); B22F 3/02 (2006.01); B22F 3/10 (2006.01); B22F 3/12 (2006.01); B22F 10/10 (2021.01); B22F 10/14 (2021.01); B33Y 10/00 (2015.01); B22F 10/20 (2021.01); B33Y 80/00 (2015.01)
CPC A61F 2/02 (2013.01) [B22F 3/004 (2013.01); B22F 3/02 (2013.01); B22F 3/10 (2013.01); B22F 3/12 (2013.01); B22F 10/10 (2021.01); B22F 10/14 (2021.01); A61F 2210/0076 (2013.01); B22F 10/20 (2021.01); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12)] 21 Claims
OG exemplary drawing
 
1. A method of producing an implant, the method comprising the steps of:
fabricating a first layer of repeated building units;
fabricating a second layer of repeated building units, each of the building units of the second layer intersecting at least one of the building units of the first layer at intersections between the first and the second layers, the first and the second layers together forming a porous section of the implant, at least some of the repeated building units of the first and the second layers define regular shapes, the building units of the first layer or the second layer include holeless beads, wherein at least some pores of the porous section are disposed between the holeless beads; and
attaching the formed porous section to a base section of an implant.