Medical Devices

Abstract

Endoprostheses including composites, and methods of making the endoprosthesis, are disclosed. The composites include at least a first material and a second material having different chemical compositions from each other.

1 - 37 . (canceled) 
   
   
       38 . A method of making an endoprosthesis, the method comprising:
 introducing a powdered second material into at least some interconnected channels defined by interconnected portions of a first structure comprising a first material to form a dry composite, the first and second materials having different chemical compositions,   consolidating the dry composite under pressure, and   using the consolidated composite to form at least a portion of the endoprosthesis.   
   
   
       39 . (canceled) 
   
   
       40 . The method of  claim 38 , further comprising agitating the first structure to distribute the powdered second material. 
   
   
       41 . (canceled) 
   
   
       42 . (canceled) 
   
   
       43 . The method of  claim 38 , wherein the step of consolidating is performed by cold pressing, sintering, or hot isostatic pressing. 
   
   
       44 . The method of  claim 56 , wherein the second material is molten when introduced into at least some of the interconnected channels in the first structure. 
   
   
       45 . The method of  claim 44 , wherein the second material has a lower melting temperature than the first structure. 
   
   
       46 . The method of  claim 44 , further comprising melting the second material by vacuum induction skull method prior to introducing it into at least some of the interconnected channels in the first structure. 
   
   
       47 . The method of  claim 44 , wherein the second material comprises titanium and the first structure comprises tantalum. 
   
   
       48 . The method of  claim 44 , wherein the first structure is placed in a mold and molten second material is introduced into the mold. 
   
   
       49 . (canceled) 
   
   
       50 . The method of  claim 38 , further comprising creating the first structure by introducing a molten first material into a mold having a ceramic core in the form of the interconnected channels and allowing the first material to harden, wherein the ceramic core extends to at least one edge of the mold;
 removing the ceramic core to leave the interconnected channels in the hardened first material.   
   
   
       51 . (canceled) 
   
   
       52 . (canceled) 
   
   
       53 . (canceled) 
   
   
       54 . (canceled) 
   
   
       55 . (canceled) 
   
   
       56 . A method of making an endoprosthesis, the method comprising:
 introducing a second material into at least some interconnected channels defined by interconnected portions of a first structure comprising a first material to form a composite, the first and second materials having different chemical compositions,   densifying the composite into a billet; and   shaping the billet to form at least a portion of the endoprosthesis.   
   
   
       57 . The method of  claim 56 , wherein the composite is densified by applying heat and isostatic pressure to the composite. 
   
   
       58 . The method of  claim 56  wherein shaping the billet to form at least a portion of the endoprosthesis comprises hot pressing, hot extruding or forging the billet to form a rod, gun drilling the rod, drawing the drilled rod into tubing and laser cutting the tubing to form the endoprosthesis. 
   
   
       59 . The method of  claim 58 , further comprising coating the endoprosthesis with a biocompatible material. 
   
   
       60 . The method of  claim 38 , wherein second material is introduced into at least 50% of the interconnected portions of the first structure. 
   
   
       61 . The method of  claim 38 , wherein the first structure is selected from the group consisting of a wire weave mesh, a braided wire, and a tangled wire. 
   
   
       62 . The method of  claim 38 , wherein the first structure is a honeycomb. 
   
   
       63 . The method of  claim 38 , wherein forming the consolidated composite into at least a portion of the endoprosthesis comprises drawing the consolidated composite into a tube. 
   
   
       64 . A method of making an endoprosthesis, the method comprising:
 introducing a second material comprising titanium into at least some interconnected channels defined by interconnected portions of a first structure comprising tantalum to form a composite, and   using the composite to form at least a portion of the endoprosthesis.   
   
   
       65 . The method of  claim 64 , wherein the first structure comprises foamed tantalum.