Method and apparatus for forming porous metal implants

1. A method for preparing a porous metal implant comprising:

a. preparing a mixture comprising:

i. a biocompatible metal powder;

ii. a spacing agent selected from the group consisting of hydrogen peroxide, urea, ammonium carbonate, ammonium bicarbonate, ammonium carbamate, calcium hydrogen phosphate, naphthalene, and mixtures thereof; and

iii. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder;

b. forming the mixture into a shape; and

c. removing the spacing agent by melting or sublimation thereof to form a plurality of pores within the metal implant.

2. The method of claim 1 , wherein the biocompatible metal powder is selected from the group consisting of titanium, titanium alloys, cobalt, cobalt alloys, chromium, chromium alloys, tantalum, tantalum alloys, and stainless steel.

3. The method of claim 1 , wherein the metal powder has a particle size of from about 5 micrometers to about 1500 micrometers.

4. The method of claim 1 , wherein the spacing agent has a particle size of from about 1 micrometer to about 1500 micrometers.

5. The method of claim 1 , wherein the non-polar liquid binder and the spacing agent form a suspension.

6. A method for preparing a porous metal implant comprising:

a. preparing a mixture comprising:

i. a biocompatible metal powder;

ii. a spacing agent; and

iii. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder;

b. forming the mixture into a shape; and

c. removing the spacing agent to form a plurality of pores within the metal implant, wherein the non-polar liquid binder comprises d-limonene.

7. The method of claim 1 , wherein the binder and the spacing agent are cohesive during formation of the mixture and removal of the spacing agent.

8. The method of claim 1 , wherein the mixture is a homogenous mixture.

9. The method of claim 1 , wherein forming the mixture into a shape comprises molding the mixture into a shape suitable for application to an augment site.

10. The method of claim 1 , wherein forming the mixture into a shape is selected from pressing techniques selected from the group consisting of uniaxial pressing, isostatic pressing, and split die techniques.

11. The method of claim 10 , wherein said forming is conducted at a temperature at or below about room temperature.

12. The method of claim 10 , wherein the pressing technique is conducted at about above 150 megapascals.

13. The method of claim 12 , wherein the pressing technique is conducted at above about 170 megapascals.

14. The method of claim 1 , wherein removing the spacing agent comprises subliming the mixture at which the metal does not react with the spacing agent.

15. The method of claim 1 , further comprising sintering the metal under vacuum pressure after removing the spacing agent.

16. The method of claim 15 , further comprising at least one of shaping the implant, machining the implant, attaching the implant to a substrate, or welding the porous implant to a substrate.

17. The method of claim 1 , wherein the metal powder includes at least two different sizes.

18. The method of claim 1 , further comprising providing a gradient porosity in the metal implant.

19. The method of claim 18 , wherein the gradient porosity is from about 1% to about 80%.

20. The method of claim 1 , further comprising coating at least a surface of the porous metal implant with an agent selected from the group consisting of resorbable ceramics, resorbable polymers, antibiotics, demineralized bone matrix, blood products, platelet concentrate, allograft, xenograft, autologous and allogeneic differentiated cells or stem cells, peptides, nutrients, vitamins, growth factors, and mixtures thereof.

21. A moldable mixture for providing a porous metal implant comprising:

a. a biocompatible metal powder;

b. a spacing agent; and

c. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder, wherein the difference in the sublimation temperature of the spacing agent and the sublimation temperature of the non-polar liquid binder is less than about 200° C.

22. The moldable mixture according to claim 21 , wherein the biocompatible metal powder comprises Ti-6Al-4V.

23. The moldable mixture according to claim 21 , wherein the spacing agent comprises ammonium bicarbonate.

24. A moldable mixture for providing a porous metal implant comprising:

a. a biocompatible metal powder;

b. a spacing agent; and

c. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder, wherein the non-polar liquid binder is d-limonene.

25. The moldable mixture according to claim 21 , further comprising a securing element.

26. A method of securing the moldable mixture of claim 25 , comprising:

a. placing a securing element about at least a portion of the mixture;

b. molding the mixture into a formed shape while the mixture is in the securing element;

c. subliming the spacing agent and non-polar liquid binder from the formed shape;

d. removing the securing element; and

e. sintering the formed shape.

27. The method of claim 26 , wherein the securing element is made of a flexible material.

28. The method of claim 27 , wherein the flexible material is selected from a metal foil, rubber, or a silicone polymer.

29. A method of securing a moldable mixture for providing a porous metal implant comprising:

a. providing a mixture comprising a biocompatible metal powder, a spacing agent, and a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder;

b. placing a securing element comprising a metal foil about at least a portion of the mixture;

c. molding the mixture into a formed shape while the mixture is in the securing element;

d. subliming the spacing agent and non-polar liquid binder from the formed shape;

e. removing the securing element; and

f. sintering the formed shape.

30. The method of claim 26 , wherein the securing element is vacuum sealed about at least a portion of the mixture.

31. A method for preparing a porous metal implant comprising:

a. preparing a mixture comprising:

i. a biocompatible metal powder;

ii. a spacing agent; and

iii. a non-polar liquid binder comprising d-limonene, wherein the spacing agent is substantially insoluble in the non-polar liquid binder;

b. forming the mixture into a shape; and

c. thermal cycling the mixture within a single heating unit to remove the spacing agent and the non-polar liquid binder and sinter the metal powder to form a plurality of pores within the metal implant.

32. The method according to claim 31 , further comprising continuously maintaining the mixture in the heating unit until the metal powder combines to form the metal implant.

33. A method for preparing a porous metal implant comprising:

a. preparing a mixture comprising:

i. a biocompatible metal powder;

ii. a spacing agent; and

iii. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder;

b. forming the mixture into a shape; and

c. thermal cycling the mixture within a single heating unit to remove the spacing agent and the non-polar liquid binder and sinter the metal powder to form a plurality of pores within the metal implant, wherein the thermal cycling includes at least one sintering and at least one quenching.

34. The method according to claim 1 , wherein the spacing agent comprises ammonium bicarbonate.

35. The method according to claim 34 , wherein the removing of the spacing agent comprises sublimation of the spacing agent.