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: 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: A titanium alloy having a Ti—Zr—X—Y formulation, wherein the X component is a Group V or Group VI metal and the Y component is an alpha stabilizer selected from aluminum, tin, silicon, oxygen, carbon, and nitrogen, where the titanium alloy is capable of being blackened in an air, oxygen, or oxygen containing environment. The alloy may have a yield strength of at least 100 ksi. The Y component may be oxygen above 1300 ppm. The Zr content may be greater than 22 weight percent. The alloy may have a lightness index of 46 or less on the CIELAB scale.

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: 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: 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: 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: 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 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 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 bone fixation device has a body including non-porous areas that provide superior long term fixation and osteointegration performance. The porous areas provide an in-growth surface in strategic sections such as the threaded section of the fixation device that allow substantially more contact area between in-growth surface and bone. The in-growth material is a network of interconnected porosity in a matrix of bio compatible, preferably titanium. Examples of bone fixation devices include bone screws, bone anchors, dental implants, and similar devices used to provide a fixation point in bone.

Abstract: A spinal implant of hybrid construction. The implant includes both porous and radiolucent elements. In this manner, the implant allows for substantial fusing of vertebrae while simultaneously allowing for useful follow-on evaluations through imaging. Furthermore, in spite of the potentially differing material character of the porous and radiolucent elements, they may nevertheless be coupled together in an interlocking configuration such that the implant exhibits the behavior of a single unitary device.

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: Provided is a powder and binder system for manufacturing sintered parts from particulate material, and a method of injection molding parts for sintering. The particulate material includes ceramic, metallic and intermetallic powders. Preferably, selected powder particles are coated with one or more additives depending on their shape and surface chemistry to create a powder system. The additives may include antioxidants, coupling agents, surfactants, elasticizing agents, dispersants, plasticizer/compatibilizers and lubricants. The surface active additives are designed to improve the interface between the powder and the binder. The powder system may be mixed or compounded with a binder system in an inert atmosphere to form a powder and binder system, or feedstock, for powder molding. The binder system, may contain one or more components which are removed prior to the sintering the powder. The powder and binder system may also be molded about an expendable core which is extracted prior to sintering.