US 12,102,538 B2
Surface modified unit cell lattice structures for optimized secure freeform fabrication
Nicholas Nai Guang Dong, Little Falls, NJ (US); Matthew P. Poggie, Montclair, NJ (US); Robert W. Klein, Orangeburg, NY (US); Eric Jones, Limerick (IE); Christopher J. Sutcliffe, Liverpool (GB); Joseph Robinson, Ridgewood, NJ (US); Dan Jones, Limerick (IE); Lewis Mullen, Mahwah, NJ (US); and Robin Stamp, Montclair, NJ (US)
Assigned to Howmedica Osteonics Corp., Mahwah, NJ (US); and The University Of Liverpool, Liverpool (GB)
Filed by Howmedica Osteonics Corp., Mahwah, NJ (US); and The University Of Liverpool, Liverpool (GB)
Filed on Jun. 29, 2023, as Appl. No. 18/216,345.
Application 18/216,345 is a continuation of application No. 16/804,740, filed on Feb. 28, 2020, granted, now 11,759,323.
Application 16/804,740 is a continuation of application No. 14/877,548, filed on Oct. 7, 2015, granted, now 10,614,176, issued on Apr. 7, 2020.
Application 14/877,548 is a continuation of application No. 13/618,218, filed on Sep. 14, 2012, granted, now 9,180,010, issued on Nov. 10, 2015.
Application 13/618,218 is a continuation in part of application No. 13/441,154, filed on Apr. 6, 2012, granted, now 9,135,374, issued on Sep. 15, 2015.
Prior Publication US 2023/0346562 A1, Nov. 2, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. A61F 2/30 (2006.01); A61F 2/28 (2006.01); B22F 10/28 (2021.01); B22F 10/80 (2021.01); B23K 15/00 (2006.01); B23K 26/342 (2014.01); B33Y 50/00 (2015.01); B33Y 80/00 (2015.01); G06F 30/00 (2020.01)
CPC A61F 2/30767 (2013.01) [A61F 2/28 (2013.01); A61F 2/30942 (2013.01); B22F 10/28 (2021.01); B22F 10/80 (2021.01); B23K 15/0086 (2013.01); B23K 26/342 (2015.10); B33Y 50/00 (2014.12); G06F 30/00 (2020.01); A61F 2002/30952 (2013.01); B33Y 80/00 (2014.12); Y02P 10/25 (2015.11)] 20 Claims
OG exemplary drawing
 
1. An orthopedic implant comprising:
a first implant structure corresponding to a computer-aided design (CAD) model prepared by the steps of:
populating, via one or more computer processors, a space including a porous CAD volume with cells on or overlapping a boundary of the porous CAD volume;
populating, via the one or more computer processors, the cells with porous geometries, the porous geometries having a plurality of struts having opposing ends, each end being connected at a corresponding node, the plurality of struts including at least a first strut intersecting the boundary, the first strut having a length, one end connected at a first node at a first location either (i) on the boundary or (ii) outside the porous CAD volume, and another end connected at a second node at a second location either (i) on the boundary or inside the porous CAD volume when the first node is outside the porous CAD volume or (ii) inside the porous CAD volume when the first node is on the boundary, the length of the first strut being defined between the first and the second nodes; and
removing, via the one or more computer processors, only all struts entirely outside the boundary of the porous CAD volume such that each end of the remaining struts remains connected at its corresponding node.