US 12,128,479 B2
DMLS orthopedic intramedullary device and method of manufacture
Darren J. Wilson, York (GB); David B. Harness, Eads, TN (US); and Henry Faber, Memphis, TN (US)
Assigned to Smith & Nephew, Inc., Memphis, TN (US)
Filed by Smith & Nephew, Inc., Memphis, TN (US)
Filed on Sep. 4, 2019, as Appl. No. 16/560,703.
Application 16/560,703 is a continuation of application No. 15/302,899, abandoned, previously published as PCT/US2015/025429, filed on Apr. 10, 2015.
Claims priority of provisional application 61/978,804, filed on Apr. 11, 2014.
Claims priority of provisional application 61/978,806, filed on Apr. 11, 2014.
Prior Publication US 2019/0388128 A1, Dec. 26, 2019
Int. Cl. B22F 10/364 (2021.01); A61B 17/72 (2006.01); B22F 3/15 (2006.01); B22F 5/10 (2006.01); B22F 10/28 (2021.01); B22F 10/64 (2021.01); B22F 10/66 (2021.01); B23K 26/08 (2014.01); B23K 26/10 (2006.01); B23K 26/354 (2014.01); B24C 1/08 (2006.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); C22C 14/00 (2006.01); C22F 1/18 (2006.01); A61B 17/00 (2006.01); B22F 3/24 (2006.01); B22F 10/366 (2021.01)
CPC B22F 10/364 (2021.01) [A61B 17/72 (2013.01); A61B 17/7225 (2013.01); A61B 17/7233 (2013.01); B22F 3/15 (2013.01); B22F 5/10 (2013.01); B22F 10/28 (2021.01); B23K 26/08 (2013.01); B23K 26/103 (2013.01); B23K 26/354 (2015.10); B24C 1/086 (2013.01); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12); C22C 14/00 (2013.01); C22F 1/183 (2013.01); A61B 2017/00526 (2013.01); B22F 2003/248 (2013.01); B22F 10/366 (2021.01); B22F 10/64 (2021.01); B22F 10/66 (2021.01); B22F 2998/10 (2013.01); Y02P 10/25 (2015.11)] 17 Claims
OG exemplary drawing
 
1. A method for manufacturing an orthopedic device comprising:
forming an orthopedic component via an additive manufacturing process by:
laser sintering a titanium powder to form a first plurality of laser sintered layers that define a pre-determined shape for the orthopedic component; and
selectively re-melting the first plurality of laser sintered layers, wherein the re-melting comprises a laser raster wherein a portion of a layer of the first plurality of laser sintered layers is double scanned;
heat treating the orthopedic component; and
after the heat treating, machining the orthopedic component to form the orthopedic device, wherein a wall of the orthopedic device has a variable thickness to alter a stiffness of the orthopedic device.