Implant fusion device and method of manufacturing
The present invention relates to an implant fusion device and a method of manufacturing an implant fusion device. More particularly an orthopedic or spinal implant configured to be implanted between adjacent vertebrae or within a gap in a bone or between bones, the device having a manufactured body structure simulating the physical characteristics of trabecular bone, but with improved osteoinductive features on the exterior surface wherein the device is fabricated using 3D printing. Alternatively, the implant may be made through 3D printing in a manner that results in a relatively or completely solid structure, but with a surface that mimics trabecular bone structure.
1 . A method of making a spinal implant device or orthopedic device or bone implant device, the method comprising: producing a structure through a three-dimensional (3D) printing additive process so that at an exterior portion of the structure comprises a plurality of interconnected struts that are curved or arched and spaced between open connections forming a porous wall having a porosity of between 75%-95%, wherein the structure is then further processed, after the 3D printing additive process is complete, with a laser etching technology that results in a nanotechnology structure comprising a plurality of nano channels arranged in a network on at least a first and second exterior surface of the interconnected struts that facilitates bone attachment and growth, wherein the laser etching is independent of topography of the exterior surface and wherein the plurality of nano channels have variable depth.
2 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 1 , wherein the 3D printing additive process creates a structure at the exterior surface that mimics trabecular bone structure.
3 . A method of making a spinal implant device or orthopedic device or bone implant device comprises the steps of:
fabricating an implant body structure using three-dimensional (3D) printing to create the implant body structure;
additively building the body structure having a superior load bearing surface and an inferior load bearing surface and a wall structure, wherein an outer surface or surfaces of the body structure comprises a plurality of interconnected struts that are curved or arched and spaced between open connections forming a porous portion having a porosity of between 75%-95%; and
laser etching nano channels on at least a portion of interconnected struts of at least a first and second outer surface of the implant body structure after the 3D printing is completed, wherein the laser etching is independent of topography of the first and second outer surface and wherein the nano channels have variable depth;
wherein the body structure has at least a portion having the plurality of interconnected struts forming porous walls with openings extending inwardly from an exterior surface to a depth of 1.0 mm or greater forming the porous portion with a void volume to solid mass volume mimicking trabecular bone.
4 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 3 , wherein the average or nominal ratio of void volume to mass volume in the porous portion is in a range of 65 percent or more, replicating that of trabecular bone in an adult male.
5 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 4 , wherein the struts of the porous walls are curved or arch shaped with openings communicating with adjacent walls.
6 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 5 , wherein the porous portion of the implant body structure extends at least partially across the implant body structure to the exterior surfaces forming conduits for fluid passage throughout the device.
7 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 6 , wherein the curved or arch shaped struts of the porous walls create a load bearing capacity to withstand vertical loads without collapsing.
8 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 3 , wherein the implant device has the superior load bearing surface and the inferior load bearing surface, each load bearing surface having nano channels etched on exposed surfaces.
9 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 4 , wherein the nano channels are made into a network of features in either a random pattern or an organized pattern.
10 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 9 , wherein the nano channels are formed by emitting laser beams unobstructed to surfaces within a path of the laser beams.
11 . The method of making a spinal implant fusion device of claim 9 , wherein the implant body structure is stationary and a laser moves about the implant body structure to create the network of features or wherein a laser is stationary and the implant body structure moves relative to the laser to create the network of features.
12 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 3 , further comprises the steps of:
wherein the step of fabricating includes providing the implant body structure; and the nano channels creating new bone growth attachment features to enhance osteoinductivity of the device.
13 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 12 , wherein the laser etched nano channels are made into a network of features in either a random pattern or an organized pattern.
14 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 13 , wherein the laser etching is formed by emitting laser beams unobstructed to the exterior surfaces.
15 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 14 , further comprises the step of moving a laser about the implant body structure to create the network of features.
16 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 14 , further comprises the step of moving the implant body structure about a laser to create the network of features.
17 . A method of making a spinal implant device or orthopedic device or bone implant device comprises the steps of:
fabricating an implant body structure using three-dimensional (3D) printing to create the implant body structure;
additively building the body structure having a superior load bearing surface and an inferior load bearing surface and a wall structure;
wherein the body structure has at least a portion having a plurality of walls with openings extending inwardly from an exterior surface to a depth of 1.0 mm or greater forming a porous portion with a void volume to solid mass volume mimicking trabecular bone so that the exterior surface comprises a plurality of interconnected struts that are curved or arched and spaced between open connections forming the porous portion and having a porosity of between 75%-95%; and
after the 3D printing, laser etching nano channels on at least a first and second exterior surface of the interconnected struts on at least a portion of the exterior surface or surfaces of the implant body structure, the nano channels creating new bone growth attachment features to enhance osteoinductivity of the device, wherein the laser etching is independent of topography of the exterior surface and wherein the nano channels have variable depth.
18 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 17 , wherein the average or nominal ratio of void volume to mass volume of the porous portion is in a range of 65 percent or more, replicating that of trabecular bone in an adult male.
19 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 17 , wherein one or more of the plurality of walls is curved or arch shaped with openings communicating with adjacent walls.
20 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 17 , wherein the porous portion of the implant body structure extends across the implant body structure from the exterior surfaces inwardly forming conduits for fluid passage throughout the porous portion of the implant body structure.
21 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 20 , wherein the curved or arch shaped walls create a load bearing capacity to withstand vertical loads without collapsing.
22 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 17 , wherein the implant device has the superior load bearing surface and the inferior load bearing surface having nano channels etched on exposed surfaces.
23 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 22 , wherein the nano channels are made into a network of features in either a random pattern or an organized pattern.
24 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 17 , wherein the nano channels are formed by emitting laser beams unobstructed to surfaces within a path of the laser beams.
25 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 23 , wherein the implant body structure is stationary and a laser moves about the implant body structure to create the network of features.
26 . The method of making a spinal implant device or orthopedic device or bone implant device of claim 23 , wherein a laser is stationary and the implant body structure moves relative to the laser to create the network of features.