Patents by Inventor Christopher J. Sutcliffe

Christopher J. Sutcliffe has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20200086625
    Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
    Type: Application
    Filed: November 21, 2019
    Publication date: March 19, 2020
    Applicant: The University Of Liverpool
    Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
  • Publication number: 20200023435
    Abstract: A High Energy Beam Processing (HEBP) system provides feedback signal monitoring and feedback control for the improvement of process repeatability and three-dimensional (3D) printed part quality. Electrons deflected from a substrate in the processing area impinge on a surface of a sensor. The electrons result from the deflection of an electron beam from the substrate. Either one or both of an initial profile of an electron beam and an initial location of the electron beam relative to the substrate are determined based on a feedback electron signal corresponding to the impingement of the electrons on the surface of the sensor. With an appropriate profile and location of the electron beam, the build structure is fabricated on the substrate.
    Type: Application
    Filed: July 18, 2019
    Publication date: January 23, 2020
    Inventors: Christopher J. Sutcliffe, Eric Jones, Hay Wong
  • Patent number: 10525688
    Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
    Type: Grant
    Filed: March 27, 2015
    Date of Patent: January 7, 2020
    Assignees: Howmedica Osteonics Corp., The University Of Liverpool
    Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
  • Patent number: 10398559
    Abstract: A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.
    Type: Grant
    Filed: May 13, 2014
    Date of Patent: September 3, 2019
    Assignees: Howmedica Osteonics Corp., The University Of Liverpool
    Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
  • Publication number: 20180055641
    Abstract: A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.
    Type: Application
    Filed: October 19, 2017
    Publication date: March 1, 2018
    Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
  • Publication number: 20170014235
    Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
    Type: Application
    Filed: September 27, 2016
    Publication date: January 19, 2017
    Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
  • Patent number: 9456901
    Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
    Type: Grant
    Filed: July 29, 2010
    Date of Patent: October 4, 2016
    Assignees: Howmedica Osteonics Corp., The University Of Liverpool
    Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
  • Publication number: 20160098495
    Abstract: Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a boundary is prepared. A space including the porous CAD volume is populated with unit cells. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. The space is populated with at least one elongated fixation element extending beyond the boundary to produce an interlocking feature enabling assembly or engagement with a mating structure.
    Type: Application
    Filed: October 7, 2015
    Publication date: April 7, 2016
    Inventors: Nicholas Nai Guang Dong, Matthew P. Poggie, Robert W. Klein, Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen, Robin Stamp
  • Patent number: 9180010
    Abstract: Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a boundary is prepared. A space including the porous CAD volume is populated with unit cells. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. The space is populated with at least one elongated fixation element extending beyond the boundary to produce an interlocking feature enabling assembly or engagement with a mating structure.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: November 10, 2015
    Assignees: Howmedica Osteonics Corp., The University Of Liverpool
    Inventors: Nicholas Nai Guang Dong, Matthew P. Poggie, Robert W. Klein, Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen, Robin Stamp
  • Publication number: 20150258735
    Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
    Type: Application
    Filed: March 27, 2015
    Publication date: September 17, 2015
    Applicants: HOWMEDICA OSTEONICS CORP., THE UNIVERSITY OF LIVERPOOL
    Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
  • Patent number: 9135374
    Abstract: Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a predefined portion of a boundary. A space including the porous CAD volume is populated with unit cells overlapping the predefined portion of the boundary. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. At least a first strut overlaps the predefined portion of the boundary and has a length, a first node outside the porous CAD volume, and a second node inside the porous CAD volume. All struts entirely outside the porous CAD volume are removed. After removal of the struts entirely outside the porous CAD volume, each of the remaining struts is connected to a node at each end thereof.
    Type: Grant
    Filed: April 6, 2012
    Date of Patent: September 15, 2015
    Assignees: Howmedica Osteonics Corp., The University Of Liverpool
    Inventors: Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen
  • Patent number: 8992703
    Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
    Type: Grant
    Filed: September 6, 2012
    Date of Patent: March 31, 2015
    Assignees: Howmedica Osteonics Corp., The University of Liverpool
    Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
  • Publication number: 20140249643
    Abstract: A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.
    Type: Application
    Filed: May 13, 2014
    Publication date: September 4, 2014
    Applicants: The University of Liverpool, Howmedica Osteonics Corp.
    Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
  • Patent number: 8728387
    Abstract: A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.
    Type: Grant
    Filed: December 6, 2005
    Date of Patent: May 20, 2014
    Assignees: Howmedica Osteonics Corp., The University of Liverpool
    Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
  • Patent number: 8556981
    Abstract: An implant having a porous tissue ingrowth structure and a bearing support structure is disclosed. The implant includes a metal insert having a bone ingrowth structure, an intermediate structure and a bearing support structure. A bearing surface is formed from a polymer material and attached to the bearing support structure. The intermediate structure has a porosity sufficient to inhibit the polymer material from translating through the bearing support structure to the bone ingrowth structure.
    Type: Grant
    Filed: September 18, 2009
    Date of Patent: October 15, 2013
    Assignee: Howmedica Osteonics Corp.
    Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
  • Publication number: 20130264749
    Abstract: Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a predefined portion of a boundary. A space including the porous CAD volume is populated with unit cells overlapping the predefined portion of the boundary. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. At least a first strut overlaps the predefined portion of the boundary and has a length, a first node outside the porous CAD volume, and a second node inside the porous CAD volume. All struts entirely outside the porous CAD volume are removed. After removal of the struts entirely outside the porous CAD volume, each of the remaining struts is connected to a node at each end thereof.
    Type: Application
    Filed: April 6, 2012
    Publication date: October 10, 2013
    Applicant: STRYKER IRELAND LTD.
    Inventors: Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen
  • Publication number: 20130268085
    Abstract: Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a boundary is prepared. A space including the porous CAD volume is populated with unit cells. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. The space is populated with at least one elongated fixation element extending beyond the boundary to produce an interlocking feature enabling assembly or engagement with a mating structure.
    Type: Application
    Filed: September 14, 2012
    Publication date: October 10, 2013
    Applicants: THE UNIVERSITY OF LIVERPOOL, Howmedica Osteonics Corp.
    Inventors: Nicholas Nai Guang Dong, Matthew P. Poggie, Robert W. Klein, Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen, Robin Stamp
  • Publication number: 20130056912
    Abstract: The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.
    Type: Application
    Filed: September 6, 2012
    Publication date: March 7, 2013
    Applicant: HOWMEDICA OSTEONICS CORP.
    Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
  • Patent number: 8350186
    Abstract: A method of producing an orthopedic implant including the steps of building a flat open model of at least a portion of an implant. The flat open model may be built using a selective laser sinter process. The flat open model preferably includes at least one groove along either a first surface or a second surface of the model. Next a force may be applied to the flat open model at predetermined locations to thereby cause the model to bend and assume a shape similar to a desired result. The now bent model may be resurfaced by either applying additional material such that the bent flat open model assumes the shape of a desired implant or the bent open model may be snap fit to an additional element.
    Type: Grant
    Filed: December 29, 2006
    Date of Patent: January 8, 2013
    Assignee: Howmedica Osteonics Corp.
    Inventors: Eric Jones, Christopher J. Sutcliffe, Aiguo Wang, Daniel E. Lawrynowicz
  • Patent number: 8268099
    Abstract: A method of fabricating a porous or partially porous three-dimensional metal article for use as a tissue ingrowth surface on a prosthesis. The porous article is formed using direct laser remelting in a cross section of a layer of metallic powder on a build platform without fusing thereto. The power, speed, spot size and beam overlap of the scanning laser is coordinated so that a predetermined porosity of the metallic powder can be achieved. Laser factors also vary depending from the thickness of the powder layer, type of metallic powder and size and size distribution of the powder particles. Successive depositing and remelting of individual layers are repeated until the article is fully formed by a layer-by-layer fashion. In an additional embodiment, a first layer of metallic powder may be deposited on a solid base or core and fused thereto.
    Type: Grant
    Filed: April 22, 2009
    Date of Patent: September 18, 2012
    Assignee: Howmedica Osteonics Corp.
    Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones