Abstract: A method of modifying the physical characteristics of a base titanium alloy article previously manufactured through a selective melting process is disclosed. The method includes introducing hydrogen through a thermohydrogen process to the base titanium alloy article, the resulting titanium alloy article exhibiting an isotropic and fine grained equiaxed microstructure. The thermohydrogen process may include introducing hydrogen into the base titanium alloy article to lower the beta transus temperature, heating the base titanium article above the lowered beta transus temperature to form hydrided beta, lowering the temperature of the base titanium alloy article to affect a eutectoid transformation, and dehydriding the base titanium alloy article via vacuum heating. The base titanium alloy article may have an elevated oxygen content and/or hydrogen may be introduced at 0.4 weight percent or greater.

Abstract: A vascular access port includes a base with a floor. A cap is engaged with the base to form a reservoir above the floor as a septum seals the reservoir in a fluid-tight manner. An outlet is in fluid communication with the reservoir. At least one of the base and cap is formed by metal injection molding. The cap and base may be engaged with a snap fit connection or a rotatable connection. The fluid communication may be along a non-tangential non-radial flow path. The flow path may be asymmetrical and may also include textured walls.

Abstract: A method of forming a firearm suppressor baffle including preparing a titanium alloy powder system, forming of the powder system into a green shape, optionally green machining the green shape, sintering the green shape to create a firearm suppressor baffle formed from sintered material, where the firearm suppressor baffle has an elevated oxygen content of between 0.2 and 0.5 weight percent. The resultant sintered material may have a creep value of less than 1.5% at 50 hours at 450 C. Also, a method of forming a firearm suppressor baffle including preparing a titanium aluminide powder system, forming the titanium aluminide powder system into a green shape through one of compaction and powder metal injection molding, and sintering the green shape to create the firearm suppressor baffle. The titanium aluminide powder method may also include deoxygenating the firearm suppressor baffle. Also disclosed are baffles and suppressors formed using these methods.

Abstract: High strength implantable devices having complex surfaces are injection molded from powder metal wherein the surface is defined by a monolithic insert made by additive manufacturing. The insert defines the surface texture of the device and may also include a portion to form an ingrowth texture and a portion to form a substrate interface texture. The tensile bond strength of the texture is 20 Mega Pascal or greater.

Abstract: In one embodiment, the present invention may be a method of making a porous biocompatible metal article by combining a metal powder with a homogenizing aid to form metal granules, including blending the metal granules and an extractable particulate to form a composite, forming the composite into a green article, removing the extractable particulate from the green article to form a metal matrix and pore structure, and sintering the metal matrix and pore structure. Furthermore the present invention may include a second homogenizing aid combined with the extractable particulate. The present invention also includes shaping the metal matrix and pore structure with or without the use of a binder.

Abstract: In one embodiment, the present invention may be a method of making a porous biocompatible metal article by combining a metal powder with a homogenizing aid to form metal granules, including blending the metal granules and an extractable particulate to form a composite, forming the composite into a green article, removing the extractable particulate from the green article to form a metal matrix and pore structure, and sintering the metal matrix and pore structure. Furthermore the present invention may include a second homogenizing aid combined with the extractable particulate. The present invention also includes shaping the metal matrix and pore structure with or without the use of a binder.

Abstract: In one embodiment, the present invention is a porous article including a porous portion with an average ratio between about 2:1 and about 5:1 of major pore size to minor pore size, having a substantially uniform pore distribution and a porosity of at least 70 percent, the porous article for use as a biological implant. The biological implant can be, for example, an acetabular cup.

Abstract: In one embodiment, the present invention is a porous article including a porous portion with an average ratio between about 2:1 and about 5:1 of major pore size to minor pore size, having a substantially uniform pore distribution and a porosity of at least 70 percent, the porous article for use as a biological implant. The biological implant can be, for example, an acetabular cup.

Abstract: An article of controlled porosity. The porosity of the article may be controlled by display of a particular pore character with respect to pore size, morphology and distribution through a metal, including a uniform distribution. The uniform distribution of porosity within the metal may be provided by a way of a coated pore former including a homogenizing agent thereat to maintain a uniform distribution of pore former throughout a mixture of the coated pore former and a powdered metal. A metal article may be formed of varying layers of porous metals each formed from an independent mixture of coated pore former and metal as indicated.

Abstract: In one embodiment, the present invention may be a method of making a porous biocompatible metal article by combining a metal powder with a homogenizing aid to form metal granules, including blending the metal granules and an extractable particulate to form a composite, forming the composite into a green article, removing the extractable particulate from the green article to form a metal matrix and pore structure, and sintering the metal matrix and pore structure. Furthermore the present invention may include a second homogenizing aid combined with the extractable particulate. The present invention also includes shaping the metal matrix and pore structure with or without the use of a binder.

Abstract: A porous metal article having a predetermined pore structure. The porosity is provided by the use of an extractable particulate in a powder forming route to create a desired porosity. Extraction of the pore forming particulate prior to sintering of the powder minimizes contamination of the sintered article and allows for the processing of material sensitive to contamination such as titanium. Added functionality can be gained by co-forming the porous material with non-porous material to create an article with layers of differing characteristics. The article is suitable for use as an implant body is porous enough to facilitate tissue in-growth and bony fusion.

Abstract: A porous metal article having a predetermined pore structure. The porosity is provided by the use of an extractable particulate in a powder forming route to create a desired porosity. Extraction of the pore forming particulate prior to sintering of the powder minimizes contamination of the sintered article and allows for the processing of material sensitive to contamination such as titanium. Added functionality can be gained by co-forming the porous material with non-porous material to create an article with layers of differing characteristics. The article is suitable for use as an implant body is porous enough to facilitate tissue in-growth and bony fusion.

Abstract: Multiphase polymeric binders for binder assisted forming of sinterable powder bodies are formulated to demonstrate improved rheological properties in the form of newtonion or near newtonion flow behavior thereby reducing dependence of binder viscosity on shear by tailoring the molecular weight and molecular weight distribution of the polymeric binder phases and the resulting polymer admixtures of the invention demonstrate shear rate independent behavior. Reduction of interfacial tension between binder phases by introduction of at least one macromolecule with separate segments selected to be compatible with the individual phases of the binder further increases processing performance as does use of polymer macromolecules having attributes that allow them to act as surface active materials at the interface of the sinterable powder and the multiphase binder composition. Predispersion of the surface active materials in the powder is facilitated by emulsification thereof in water prior to admixture with the powder.