Interbody fusion devices and related methods of manufacture

Abstract

Interbody fusion devices and related methods of manufacture are described herein. An example interbody fusion device can include a plurality of vertebral endplates, and a body extending between the vertebral endplates. The body and the vertebral endplates can define an internal cavity. Additionally, each of the vertebral endplates can include a lattice structure and a frame surrounding the lattice structure, where the lattice structure being configured to distribute load. Each of the vertebral endplates can also include a plurality of micro-apertures having an average size between about 2 to about 10 micrometers (μm), and a plurality of macro-apertures having an average size between about 300 to about 800 micrometers (μm).

1 . An interbody fusion device, comprising:
 a plurality of vertebral endplates; and   a body extending between the vertebral endplates, wherein the body and the vertebral endplates define an internal cavity, and wherein each of the vertebral endplates comprises:
 a lattice structure and a frame surrounding the lattice structure, the lattice structure being configured to distribute load, 
 a plurality of micro-apertures having an average size between about 2 to about 10 micrometers (μm), 
 a plurality of macro-apertures having an average size between about 300 to about 800 micrometers (μm). 
   
     
     
         2 . The interbody fusion device of  claim 1 , wherein the lattice structure comprises a crisscrossed pattern of strips defining an array of openings, each of the openings extending between a contacting surface of one of the vertebral endplates and the internal cavity. 
     
     
         3 . The interbody fusion device of  claim 2 , wherein at least one of the openings comprises an angled corner. 
     
     
         4 . The interbody fusion device of  claim 1 , wherein each of the vertebral endplates comprises a plurality of teeth. 
     
     
         5 . The interbody fusion device of  claim 4 , wherein the teeth extend between respective lateral sides of the body. 
     
     
         6 . The interbody fusion device of  claim 4 , wherein the teeth extend across the frame and the lattice structure. 
     
     
         7 . The interbody fusion device of  claim 1 , wherein the body comprises an anterior end, a posterior end, and a pair of lateral sides extending between the anterior and posterior ends. 
     
     
         8 . The interbody fusion device of  claim 7 , wherein the anterior end and the vertebral endplates define a tapered end. 
     
     
         9 . The interbody fusion device of  claim 7 , wherein the posterior end comprises an inserter attachment element. 
     
     
         10 . The interbody fusion device of  claim 7 , wherein at least one of the lateral sides comprises at least one support column extending between the vertebral endplates. 
     
     
         11 . The interbody fusion device of  claim 7 , wherein at least one of the anterior end, the posterior end, or the lateral sides comprises a window opening. 
     
     
         12 . The interbody fusion device of  claim 1 , wherein at least one of the micro-apertures or the macro-apertures connect a contacting surface of one of the vertebral endplates to the internal cavity. 
     
     
         13 . The interbody fusion device of  claim 1 , wherein the body and the vertebral endplates are manufactured using a machining process. 
     
     
         14 . The interbody fusion device of  claim 1 , wherein the micro-apertures and the macro-apertures are manufactured using a chemical etching process. 
     
     
         15 . The interbody fusion device of  claim 1 , wherein the interior cavity is configured to accept bone fusion material. 
     
     
         16 . The interbody fusion device of  claim 15 , wherein the bone fusion material comprises at least one of demineralized bone matrix (DBM), autograft bone, allograft bone, stem cells, or synthetic material. 
     
     
         17 . The interbody fusion device of  claim 1 , wherein the vertebral endplates and the body are formed of at least one of titanium or an alloy thereof, cobalt chrome alloy, stainless steel, molybdenum rhenium (MoRe), polyether ether ketone (PEEK), polyaryletherketone (PAEK), poly(methyl methacrylate) (PMMA), or carbon fiber. 
     
     
         18 . The interbody fusion device of  claim 17 , wherein the vertebral endplates and the body are formed of molybdenum rhenium (MoRe). 
     
     
         19 . The interbody fusion device of  claim 1 , further comprising a fusion promoting or infection prevention coating layer provided on at least one of the vertebral endplates. 
     
     
         20 . The interbody fusion device of  claim 19 , wherein the fusion promoting or infection prevention coating layer comprises at least one of hydroxyapatite, a bone morphogenetic protein (BMP), an antibiotic, a porous coating, a hydrophilic coating, or silver zeolite. 
     
     
         21 . A method, comprising:
 forming from a material, using a machining process, an interbody fusion device comprising a plurality of vertebral endplates and a body extending between the vertebral endplates, wherein the body and the vertebral endplates define an internal cavity;   forming from each of the vertebral endplates, using a machining process, a lattice structure and a frame surrounding the lattice structure, the lattice structure being configured to distribute load; and   forming in each of the vertebral endplates, using a chemical etching process, a plurality of micro-apertures and a plurality of macro-apertures, wherein the micro-apertures have an average size between about 2 to about 10 micrometers (μm) and the macro-apertures have an average size between about 300 to about 800 micrometers (μm).   
     
     
         22 . The method of  claim 21 , wherein the chemical etching process comprises dipping each of the vertebral endplates in an acid. 
     
     
         23 . The method of  claim 21 , wherein the material comprises at least one of titanium or an alloy thereof, cobalt chrome alloy, stainless steel, molybdenum rhenium (MoRe), polyether ether ketone (PEEK), polyaryletherketone (PAEK), poly(methyl methacrylate) (PMMA), or carbon fiber.