Abstract: Systems and methods for fabrication of implantable medical devices using an Electron Beam Melting (EBM) manufacturing process are provided. According to one embodiment, an EBM manufacturing system is caused to perform a fabrication process that results in an implantable medical device of unitary construction having a solid volume and a porous volume. A layer of metal powder is spread across a build platform of the EBM manufacturing system. Portions of the layer of metal powder are selectively heated in accordance each portion's association with the solid volume or the porous volume by scanning the layer of metal powder with an electron beam of the EBM manufacturing system and adjusting a power of the electron beam and a speed of said scanning. The build platform is lowered based on a predetermined layer thickness and the process of continues on a layer-by-layer basis until the implantable medical device is completed.

Abstract: Systems and methods for fabrication of implantable medical devices using an Electron Beam Melting (EBM) manufacturing process are provided. According to one embodiment, an EBM manufacturing system is caused to perform a fabrication process that results in an implantable medical device of unitary construction having a solid volume and a porous volume. A layer of metal powder is spread across a build platform of the EBM manufacturing system. Portions of the layer of metal powder are selectively heated in accordance each portion's association with the solid volume or the porous volume by scanning the layer of metal powder with an electron beam of the EBM manufacturing system and adjusting a power of the electron beam and a speed of said scanning The build platform is lowered based on a predetermined layer thickness and the process of continues on a layer-by-layer basis until the implantable medical device is completed.

Abstract: Systems and methods are provided for designing and producing a custom-fit prosthesis. According to one embodiment, a mold is produced from which a custom-fit implant may be directly or indirectly manufactured. Medical image data representing surrounding portions of a patient's anatomy to be repaired by surgical implantation of the custom-fit implant are received. Then, three-dimensional surface reconstruction is performed based on the medical image data. Next, the custom-fit implant is designed based on the three-dimensional surface reconstruction and a positive or negative representation of a two-part mold is created with a void in the shape of the custom-fit implant by subtracting a representation of the custom-fit implant from a representation of a mold. Finally, the two-part mold is output from which the custom-fit implant may be directly manufactured; or an implant is directly output. Alternatively, an intermediate mold is created from which a two-part mold may be directly manufactured.

Abstract: Systems and methods for creation of anatomically correct physical models for an individual patient are provided. More specifically, the embodiments of the present invention relate to systems and methods for design and manufacture of a modified bone model including an accurate soft tissue model. Medical image acquisition processes are used to capture data representative of an anatomy and a scan prosthesis. A modified bone model with supports is designed and fabricated. The modified bone model and scan prosthesis (or copy thereof) is then used to generate the soft tissue model.