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).
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Patent number: 10525688Abstract: 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: GrantFiled: March 27, 2015Date of Patent: January 7, 2020Assignees: Howmedica Osteonics Corp., The University Of LiverpoolInventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
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Patent number: 10398559Abstract: 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: GrantFiled: May 13, 2014Date of Patent: September 3, 2019Assignees: Howmedica Osteonics Corp., The University Of LiverpoolInventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
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Publication number: 20180055641Abstract: 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: ApplicationFiled: October 19, 2017Publication date: March 1, 2018Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
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Publication number: 20170014235Abstract: 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: ApplicationFiled: September 27, 2016Publication date: January 19, 2017Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
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Patent number: 9456901Abstract: 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: GrantFiled: July 29, 2010Date of Patent: October 4, 2016Assignees: Howmedica Osteonics Corp., The University Of LiverpoolInventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
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Publication number: 20160098495Abstract: 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: ApplicationFiled: October 7, 2015Publication date: April 7, 2016Inventors: Nicholas Nai Guang Dong, Matthew P. Poggie, Robert W. Klein, Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen, Robin Stamp
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Patent number: 9180010Abstract: 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: GrantFiled: September 14, 2012Date of Patent: November 10, 2015Assignees: Howmedica Osteonics Corp., The University Of LiverpoolInventors: Nicholas Nai Guang Dong, Matthew P. Poggie, Robert W. Klein, Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen, Robin Stamp
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Publication number: 20150258735Abstract: 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: ApplicationFiled: March 27, 2015Publication date: September 17, 2015Applicants: HOWMEDICA OSTEONICS CORP., THE UNIVERSITY OF LIVERPOOLInventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
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Patent number: 9135374Abstract: 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: GrantFiled: April 6, 2012Date of Patent: September 15, 2015Assignees: Howmedica Osteonics Corp., The University Of LiverpoolInventors: Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen
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Patent number: 8992703Abstract: 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: GrantFiled: September 6, 2012Date of Patent: March 31, 2015Assignees: Howmedica Osteonics Corp., The University of LiverpoolInventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
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Publication number: 20140249643Abstract: 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: ApplicationFiled: May 13, 2014Publication date: September 4, 2014Applicants: The University of Liverpool, Howmedica Osteonics Corp.Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
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Patent number: 8728387Abstract: 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: GrantFiled: December 6, 2005Date of Patent: May 20, 2014Assignees: Howmedica Osteonics Corp., The University of LiverpoolInventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
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Patent number: 8556981Abstract: 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: GrantFiled: September 18, 2009Date of Patent: October 15, 2013Assignee: Howmedica Osteonics Corp.Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp
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Publication number: 20130268085Abstract: 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: ApplicationFiled: September 14, 2012Publication date: October 10, 2013Applicants: 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
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Publication number: 20130264749Abstract: 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: ApplicationFiled: April 6, 2012Publication date: October 10, 2013Applicant: STRYKER IRELAND LTD.Inventors: Eric Jones, Christopher J. Sutcliffe, Joe Robinson, Dan Jones, Lewis Mullen
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Publication number: 20130056912Abstract: 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: ApplicationFiled: September 6, 2012Publication date: March 7, 2013Applicant: HOWMEDICA OSTEONICS CORP.Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones, Robin Stamp
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Patent number: 8350186Abstract: 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: GrantFiled: December 29, 2006Date of Patent: January 8, 2013Assignee: Howmedica Osteonics Corp.Inventors: Eric Jones, Christopher J. Sutcliffe, Aiguo Wang, Daniel E. Lawrynowicz
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Patent number: 8268100Abstract: 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: GrantFiled: July 26, 2010Date of Patent: September 18, 2012Assignee: Howmedica Osteonics Corp.Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones
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Patent number: 8268099Abstract: 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: GrantFiled: April 22, 2009Date of Patent: September 18, 2012Assignee: Howmedica Osteonics Corp.Inventors: William O'Neill, Christopher J. Sutcliffe, Eric Jones
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Publication number: 20110014081Abstract: 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: ApplicationFiled: July 29, 2010Publication date: January 20, 2011Applicant: HOWMEDICA OSTEONICS CORP.Inventors: Eric Jones, Christopher J. Sutcliffe, Robin Stamp