Abstract: The present invention relates to a process for fabricating a composite functional body/substrate, either by melting with an energy beam or by spin coating. The functional material is preferably a piezoelectric material (PVDF). The energy beam is preferably a laser beam.

Abstract: An apparatus is disclosed for layer-on-layer manufacture of shaped three dimensional items. The process is controlled by a computer (36). The item is supported upon a build platform (2) and the apparatus additionally includes at least one build station (4) which serves to form upon the item under manufacture a layer of material having a controlled depth, and a shape determined by the computer controller. The build station and/or the build platform is/are mounted and driven to rotate about an axis. In this way the surface of the item under manufacture is repeatedly presented to the build station. The item is thereby built up from multiple layers of material. The rotational motion is advantageous in comparison with the reciprocal relative motion of existing “rapid proto-typing” machines.

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 center 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.

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.

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.