Abstract: At least a portion of an object such as a medical implant is fabricated by a process. In the process, a porous structure, a solid structure, and an interface region directly attached to each of the porous structure and the solid structure are produced by an additive manufacturing machine using a stored output file configured for providing instructions to the additive manufacturing machine for fabricating the porous structure, the solid structure, and the interface region. The stored output file is prepared by preparing a computer-generated component file including a porous CAD volume and a solid CAD volume. Digitized radii are added to digitized struts defining digitized pores in an interface volume of porous CAD volume to mitigate stress concentrations that would otherwise result in sharp corners or notches in the fabricated object.

Abstract: In one embodiment, the present invention may be a method of forming a porous and/or dense article from metal powder, including adding to a mold a first feedstock comprising an agglomerated metal powder and an agglomeration agent; forming said first feedstock into a green state dense article; and removing said agglomeration agent. Furthermore, the present invention may include a second feedstock including an agglomerated metal powder, a space filling material and an agglomeration agent which may be formed into a green state porous article. The present invention also includes a dense and/or porous article manufactured by various methods, as well as methods for creating the dense and porous feedstocks. Moreover, the present invention may include an article which may be a medical implant.

Abstract: In one embodiment, the present invention may be a method of forming a porous and/or dense article from metal powder (12), including adding to a mold a first feedstock comprising an agglomerated metal powder (12) and an agglomeration agent, forming said first feedstock into a green state dense article (22); and removing said agglomeration agent. Furthermore, the present invention may include a second feedstock including an agglomerated metal powder (12), a space filling material and an agglomeration agent which may be formed into a green state porous article (21). The present invention also includes a dense and/or porous article (22 and 21) manufactured by various methods, as well as methods for creating the dense and porous feedstocks. Moreover, the present invention may include an article which may be a medical implant.

Abstract: In one embodiment, the present invention may be a method of forming a porous and/or dense article from metal powder (12), including adding to a mold a first feedstock comprising an agglomerated metal powder (12) and an agglomeration agent, forming said first feedstock into a green state dense article (22); and removing said agglomeration agent. Furthermore, the present invention may include a second feedstock including an agglomerated metal powder (12), a space filling material and an agglomeration agent which may be formed into a green state porous article (21). The present invention also includes a dense and/or porous article (22 and 21) manufactured by various methods, as well as methods for creating the dense and porous feedstocks. Moreover, the present invention may include an article which may be a medical implant.