Granted Patent
B1
US 12,582,527 · App. 17/938,248 · Granted Mar 24, 2026
Sheet based triply periodic minimal surface implants for promoting osseointegration and methods for producing same
Inventors:
Andrew Todd Miller (Durham, NC); Matthew Rexrode (Durham, NC); Cambre Kelly (Durham, NC); Ken Gall (Durham, NC)
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Abstract
Provided herein are implants and methods for producing implants. In at least one embodiment, the implants include sheet-based, triply periodic, minimal surface (TPMS) portions. According to one embodiment, the TPMS portions include a gyroid architecture that provides for improved osseointegration and mechanical performance over previous implants due to novel ratios of porosity to compressive strength, among other features. In one or more embodiments, the gyroid architecture is organized into unit cells that demonstrate anisotropic mechanical performance along an insertion direction. In various embodiments, the present methods include novel selective laser melting (SLM) techniques for forming the TPMS portions of implants in a manner that reduces defect formation, thereby improving compressive performance and other implant properties.
Claims (33)
1 . An additively manufactured implant comprising:
a volume between a top portion and a bottom portion, the volume comprising at least one porous sheet based triply periodic minimal surface (TPMS) portion comprising a wall density of at least 99%, wherein:
the volume is integrally formed with at least one non-porous structure; and
the at least one TPMS portion comprises an ultimate compression strength of about 50.0-230.0 MPa and a porosity of about 55-85%.
2 . The additively manufactured implant of claim 1 , wherein the at least one TPMS portion is free of nodes.
3 . The additively manufactured implant of claim 2 , wherein the at least one TPMS portion is free of struts.
4 . The additively manufactured implant of claim 3 , wherein the at least one TPMS portion is defined by a plurality of unit cells, each unit cell comprising a base geometry defined by a sinusoidal equation.
5 . The 3D printed implant of claim 4 , wherein the sinusoidal equation comprises:
cos x sin y +cos y sin z +cos z sin x =0.
6 . The additively manufactured implant of claim 5 , wherein the plurality of unit cells and the at least one non-porous structure are integrally formed via powder bed fusion.
7 . The additively manufactured implant of claim 6 comprising a spinal implant.
8 . The additively manufactured implant of claim 6 comprising an osteotomy wedge.
9 . The additively manufactured implant of claim 6 comprising a custom implant.
10 . The additively manufactured implant of claim 6 comprising a custom, spherical implant for ankle reconstruction.
11 . The additively manufactured implant of claim 6 comprising a prosthetic implant.
12 . The additively manufactured implant of claim 6 comprising an implant associated with hemiarthroplasty.
13 . The additively manufactured implant of claim 6 comprising a craniomaxillofacial implant.
14 . The additively manufactured implant of claim 6 comprising a sports medicine implant.
15 . The additively manufactured implant of claim 6 comprising a dental implant.
16 . The additively manufactured implant of claim 6 comprising an arthrodesis-related implant.
17 . The additively manufactured implant of claim 6 , wherein the at least one TPMS portion comprises a wall thickness of at least 0.25 mm.
18 . The additively manufactured implant of claim 6 , wherein the at least one TPMS portion comprises a stiffness modulus of about 3.0-14.0 GPA.
19 . The additively manufactured implant of claim 6 , wherein the at least one TPMS portion comprises titanium.
20 . The additively manufactured implant of claim 6 , wherein the at least one TPMS portion comprises cobalt chromium.
21 . An additively manufactured implant comprising:
a volume between a top portion and a bottom portion, the volume comprising at least one sheet based triply periodic minimal surface (TPMS) porous portion defined by a plurality of unit cells, wherein:
each unit cell comprises a base geometry defined by a sinusoidal equation;
the at least one TPMS porous portion comprises a wall density of at least 99%;
the volume is integrally formed with at least one non-porous structure; and
the at least one TPMS porous portion comprises an ultimate compression strength of about 50.0-230.0 MPa and a porosity of about 55-85%.
22 . The additively manufactured implant of claim 21 , wherein the sinusoidal equation comprises:
cos x sin y +cos y sin z +cos z sin x =0.
23 . The additively manufactured implant of claim 22 , wherein the implant is an implant of the group comprising: a spinal implant, an osteotomy wedge, a patient-specific implant, an implant for ankle reconstruction, a prosthetic implant, a hemiarthroplasty implant, a craniomaxillofacial implant, a dental implant, and an implant for arthrodesis.
Assignments (1)
SECURITY INTEREST
Recorded Jun 7, 2024
From: RESTOR3D, INC.; CONFORMIS, INC.; IMATX, INC.
To: TRINITY CAPITAL INC., AS ADMINISTRATIVE AGENT
Reel/Frame 067679/0713 →
Continuity (3)
Continuation
17314357
· May 7, 2021
Continuation
16991638
· Aug 12, 2020
Continuation
16737341
· Jan 8, 2020
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