Granted Patent B1

US 12,653,680 · App. 17/938,249 · Granted Jun 16, 2026

Inventors: Andrew Todd Miller (Durham, NC); Matthew Rexrode (Durham, NC); Cambre Kelly (Durham, NC); Ken Gall (Durham, NC)

Assignees: RESTOR3D, INC.; DUKE UNIVERSITY

A61F2/3094A61F2/4455A61F2002/30736A61F2002/30784A61F2002/30985A61F2310/00023

Abstract

Claims (48)

1 . A three dimensional (3D)-printed spinal implant comprising:

a top surface, a bottom surface, a first side surface, a second side surface, and a back surface; and

a metal porous sheet based triply periodic minimal surface portion:

integrally formed via powder bed fusion;

forming a portion of the top surface and the bottom surface; and

defined by a plurality of unit cells, each unit cell comprising a base geometry defined by a sinusoidal equation, wherein:

the first side surface transitions to the back surface via a first rounded corner;

the second side surface transitions to the back surface via a second rounded corner;

the back surface is defined by a plane intersecting each of the rounded corners;

the porous sheet based triply periodic minimal surface portion comprises a porosity of about 55-85%;

the porous sheet based triply periodic minimal surface portion is node and strut free;

the porous sheet based triply periodic minimal surface portion comprises a wall thickness of 0.25 mm to 1.0 mm;

the porous sheet based triply periodic minimal surface portion defines an opening devoid of any structure, the opening bisecting the porous sheet based triply periodic minimal surface portion;

the top surface is devoid of teeth; and

the portion of the top surface formed by the porous sheet based triply periodic minimal surface portion defined by the sinusoidal equation is configured to directly contact bone of a patient upon implantation.

2 . The 3D-printed spinal implant of claim 1 , wherein the porous sheet based triply periodic minimal surface portion is a gyroid portion.

3 . The 3D-printed spinal implant of claim 2 , wherein the sinusoidal equation comprises:

cos x sin y +cos y sin z +cos z sin x= 0.

4 . The 3D-printed spinal implant of claim 3 , wherein the back surface defines at least one opening for receiving instrumentation.

5 . The 3D-printed spinal implant of claim 4 , wherein the back surface is devoid of ridges extending away from the back surface.

6 . The 3D-printed implant of claim 1 , wherein the porous sheet based triply periodic minimal surface portion comprises a stiffness modulus of about 3.0-14.0 GPA.

7 . The 3D-printed implant of claim 6 , wherein the porous sheet based triply periodic minimal surface portion comprises an ultimate compression strength of about 50.0-230.0 MPa.

8 . The 3D-printed implant of claim 7 , wherein the porous sheet based triply periodic minimal surface portion comprises a wall density greater than of at least 99%.

9 . A 3D-printed spinal implant comprising:

a top surface and a bottom surface; and

a metal porous sheet based triply periodic minimal surface portion:

integrally formed via Selective Laser Melting (SLM) 3D printing;

forming at least a portion of the top surface and the bottom surface; and

defined by a plurality of unit cells, each unit cell comprising a base geometry defined by a base equation:

cos x sin y +cos y sin z +cos z sin x= 0

wherein:

the porous sheet based triply periodic minimal surface portion comprises a porosity of about 55-85%;

the porous sheet based triply periodic minimal surface portion is node and strut free;

the porous sheet based triply periodic minimal surface portion comprises a wall thickness of 0.25 mm to 1.0 mm;

the porous sheet based triply periodic minimal surface portion defines an opening devoid of any structure, the opening bisecting the porous portion;

the porous sheet based triply periodic minimal surface portion comprises an ultimate compression strength of about 50.0-230.0 MPa;

the top surface is devoid of teeth; and

the portion of the top surface formed by the porous sheet based triply periodic minimal surface portion defined by the base equation is configured to directly contact bone of a patient upon implantation.

10 . The 3D-printed spinal implant of claim 9 , wherein the spinal implant comprises a back surface, a first side surface, and a second side surface.

11 . The 3D-printed spinal implant of claim 10 , wherein:

the first side surface transitions to the back surface via a first rounded corner; and

the second side surface transitions to the back surface via a second rounded corner.

12 . The 3D-printed spinal implant of claim 11 , wherein the back surface is defined by a plane intersecting with each of the rounded corners.

13 . The 3D-printed spinal implant of claim 12 , wherein the back surface defines at least one opening for receiving instrumentation.

14 . The 3D-printed spinal implant of claim 13 , wherein the back surface is devoid of ridges extending away from the back surface.

15 . The 3D-printed spinal implant of claim 14 , wherein the porous sheet based triply periodic minimal surface portion is a gyroid portion.

16 . The 3D-printed implant of claim 9 , wherein the porous sheet based triply periodic minimal surface portion comprises a stiffness modulus of about 3.0-14.0 GPA.

17 . The 3D-printed implant of claim 9 , wherein the porous sheet based triply periodic minimal surface portion comprises a wall density greater than of at least 99%.

Assignments (1)

Continuity (3)

References Cited (400)