Metallic structures having porous regions from imaged bone at pre-defined anatomic locations

Abstract

An additively manufactured medical implant, comprising a metallic body having at least one porous surface configured to promote bony on-growth or in-growth of tissue, the porous surface being replicated from a high resolution scan of bone, and a biological surface coating configured to create a barrier to particulate debris, the biological surface coating being produced from a titanium porous plasma spray surface coating or a biomimetic coating.

What is claimed is: 
     
         1 . A medical implant, comprising:
 a metallic body having at least one surface replicated from a high resolution scan of bone and configured to promote bony on-growth or in-growth of tissue;   wherein the implant is generated using an additive manufacturing technique   
     
     
         2 . The medical implant of  claim 1 , further comprising a biological surface coating configured to create a barrier to particulate debris. 
     
     
         3 . The medical implant of  claim 1 , wherein the biological surface coating is a titanium porous plasma spray surface coating or a biomimetic coating. 
     
     
         4 . The medical implant of  claim 3 , wherein the biological surface coating is capable of exhibiting an enhanced biological performance when subjected to at least one of grit blasting, hyaluronic acid (HA), an RGD-containing glycoprotein or bend coating. 
     
     
         5 . The medical implant of  claim 1 , wherein the at least one surface is a porous surface. 
     
     
         6 . The medical implant of  claim 1 , wherein the additive manufacturing technique used to generate the implant is selected from a Direct Metal Laser Sintering (DMLS) process or an Electron Beam Melting (EBM) process, Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), Stereolithography (SLA), Laminated Object Manufacturing, Powder Bed and Inkjet Head 3D Printing and Plaster-Based 3D Printing (PP). 
     
     
         7 . The medical implant of  claim 1 , wherein the high resolution scan of the bone comprises a scan that was imaged with a computed tomography (CT) scanner. 
     
     
         8 . The medical implant of  claim 1 , wherein the implant is configured to be implanted into a hip, shoulder, knee, spine, elbow, wrist, ankle, finger or toe. 
     
     
         9 . An additively manufactured medical implant, comprising:
 a metallic body having at least one porous surface configured to promote bony on-growth or in-growth of tissue, the porous surface being replicated from a high resolution scan of bone; and   a biological surface coating configured to create a barrier to particulate debris, the biological surface coating being produced from a titanium porous plasma spray surface coating or a biomimetic coating;   wherein the medical implant is produced from the steps of:
 imaging bone with a high resolution digital scanner to generate a three-dimensional design model of the bone; 
 removing a three-dimensional section from the design model; 
 fabricating a porous region on a digital representation of the implant by replacing a solid portion of the digital implant with the section removed from the design model; and 
 using an additive manufacturing technique to create a physical implant including the fabricated porous region. 
   
     
     
         10 . The additively manufactured medical implant of  claim 9 , wherein the production step of imaging the bone with a high resolution digital scanner comprises scanning the bone with a computed tomography (CT) scanner. 
     
     
         11 . The additively manufactured medical implant of  claim 10 , wherein the production step of scanning the bone with a computed tomography (CT) scanner comprises scanning the bone with a MicroCT scanner. 
     
     
         12 . The additively manufactured medical implant of  claim 9 , further comprising the production step of modifying any artifacts from the three-dimensional design model of the bone. 
     
     
         13 . The additively manufactured medical implant of  claim 12 , wherein the production step of modifying any artifacts from the three-dimensional design model comprises removing defective regions of the design model containing non-uniformities or discontinuities by filling the defective regions with a selected and superimposed region of the bone model that does not contain a non-uniformity or a discontinuity. 
     
     
         14 . The additively manufactured medical implant of  claim 9 , further comprising the production step of converting the imaged bone to a digital file format. 
     
     
         15 . The additively manufactured medical implant of  claim 9 , wherein the production step of fabricating a porous region on a digital representation of the implant comprises utilizing a computer aided design (CAD) program to fabricate a porous region that structurally replicates the architecture of the bone, the porous region being selected from one of a hip, shoulder, knee, spine, elbow, wrist, ankle, finger and toe. 
     
     
         16 . The additively manufactured medical implant of  claim 9 , wherein the production step of using an additive manufacturing technique to create a physical implant comprises using a Direct Metal Laser Sintering ( 1 )MLS) process or an Electron Beam Melting (EBM) process, Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), Stereolithography (SLA), Laminated Object Manufacturing, Powder Bed and Inkjet Head 3D Printing and Plaster-Based 3D Printing (PP). 
     
     
         17 . The additively manufactured medical implant of  claim 9 , further comprising the production step of performing an additional manufacturing process on the physical implant to modify one or more features, the manufacturing process being selected from at least one of casting, molding, forming, machining, joining, polishing, blasting and welding. 
     
     
         18 . An additively manufactured medical implant, comprising:
 a metallic body having at least one porous surface configured to promote bony on-growth or in-growth of tissue, the porous surface being replicated from a high resolution scan of bone; and   a biological surface coating configured to create a barrier to particulate debris, the biological surface coating being produced from a titanium porous plasma spray surface coating or a biomimetic coating;   wherein the medical implant is produced from the steps of:
 creating a digital image of the bone with a microCT scanner; 
 removing any defective artifacts from the digital image; 
 converting the digital image to a three-dimensional design model of the bone; 
 removing a three-dimensional section that structurally replicates the architecture of the bone from the design model; 
 printing the removed design model section on a digital representation of the implant; and 
 creating a physical implant from the printed digital representation by using an additive manufacturing technique. 
   
     
     
         19 . The additively manufactured medical implant of  claim 18 , wherein the production step of printing the removed design model section on a digital representation of the implant comprises using a computer aided design (CAD) program to print the removed design model section. 
     
     
         20 . The additively manufactured medical implant of  claim 18 , wherein the production step of removing any defective artifacts comprises removing any defective regions containing a non-uniformity or discontinuity from the image by filling the defective regions with a selected and superimposed region of the digital image that does not contain a non-uniformity or a discontinuity.