Abstract: A packaging system includes a packaging unit and an article. The packaging unit includes a solid layer, a porous layer and a plastic layer with a cavity. The cavity is configured to receive and secure the article in an opening defined by the cavity that is flexible between a first and a second dimension. The packaging unit is fabricated by a 3D printing process. A tensioning device of a 3D printing machine tensions a feed filament during the 3D printing process.

Abstract: A system for bone resurfacing or total hip replacement, including an acetabular component having a first cavity, a dual mobility liner having a second cavity, the outer surface of the liner being configured to be received within the first cavity and articulable therein relative to the inner surface of the acetabular component and a femoral component having a head and a stem extending from the head and being configured to be received within a femur, an outer surface of the head being configured to be received within the second cavity. The dual mobility liner includes a plurality of openings that extend from an outer surface of the liner to an inner surface of the liner, such that the plurality of openings facilitate fluid communication between opposing sides of the liner.

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.

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.

Abstract: A porous apparatus includes a first layer and a second layer. The second layer has a plurality of struts. At least some of the struts define a porous geometry defining a plurality of faces, at least one of the plurality of the faces at least partially confronting the first layer. Each face is bounded by intersecting struts at vertices. Less than all of the vertices of each face of the porous geometry at least partially confronting the first layer are connected by a strut to the first layer. A process of producing the at least partially porous structure includes depositing and scanning metal powder layers. At least some of the scanned metal powder layers form either one or both of a portion of a first section of the structure and a portion of a second section of the structure formed by at least the struts defining the porous geometry.

Abstract: An implant is produced by fabricating first and second layers. The first layer of repeated and truncated building units is fused together to define pores. The second layer of repeated and truncated building units are fused together to define pores and fused onto the first layer of truncated building units. The first and the second layers form at least part of a porous portion of the implant. The formed porous portion is attached onto a base portion of an implant. The truncated building units of each of the first and the second layers are in the form of spatially overlapping three-dimensional shapes.

Abstract: A porous apparatus includes a first layer and a second layer. The second layer has a plurality of struts. At least some of the struts define a porous geometry defining a plurality of faces, at least one of the plurality of the faces at least partially confronting the first layer. Each face is bounded by intersecting struts at vertices. Less than all of the vertices of each face of the porous geometry at least partially confronting the first layer are connected by a strut to the first layer. A process of producing the at least partially porous structure includes depositing and scanning metal powder layers. At least some of the scanned metal powder layers form either one or both of a portion of a first section of the structure and a portion of a second section of the structure formed by at least the struts defining the porous geometry.

Abstract: A porous apparatus includes a first layer and a second layer. The second layer has a plurality of struts. At least some of the struts define a porous geometry defining a plurality of faces, at least one of the plurality of the faces at least partially confronting the first layer. Each face is bounded by intersecting struts at vertices. Less than all of the vertices of each face of the porous geometry at least partially confronting the first layer are connected by a strut to the first layer. A process of producing the at least partially porous structure includes depositing and scanning metal powder layers. At least some of the scanned metal powder layers form either one or both of a portion of a first section of the structure and a portion of a second section of the structure formed by at least the struts defining the porous geometry.

Abstract: A packaging system includes a packaging unit and an article. The packaging unit includes a solid layer, a porous layer and a plastic layer with a cavity. The cavity is configured to receive and secure the article in an opening defined by the cavity that is flexible between a first and a second dimension. The packaging unit is fabricated by a 3D printing process. A tensioning device of a 3D printing machine tensions a feed filament during the 3D printing process.

Abstract: A packaging system includes a packaging unit and an article. The packaging unit includes a solid layer, a porous layer and a plastic layer with a cavity. The cavity is configured to receive and secure the article in an opening defined by the cavity that is flexible between a first and a second dimension. The packaging unit is fabricated by a 3D printing process. A tensioning device of a 3D printing machine tensions a feed filament during the 3D printing process.

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.

Abstract: A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations at least a first segment overlapping a second segment and underlapping a third segment is formed.

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.

Abstract: A packaging system includes a packaging unit and an article. The packaging unit includes a solid layer, a porous layer and a plastic layer with a cavity. The cavity is configured to receive and secure the article in an opening defined by the cavity that is flexible between a first and a second dimension. The packaging unit is fabricated by a 3D printing process. A tensioning device of a 3D printing machine tensions a feed filament during the 3D printing process.

Abstract: A porous apparatus includes a first layer and a second layer. The second layer has a plurality of struts. At least some of the struts define a porous geometry defining a plurality of faces, at least one of the plurality of the faces at least partially confronting the first layer. Each face is bounded by intersecting struts at vertices. Less than all of the vertices of each face of the porous geometry at least partially confronting the first layer are connected by a strut to the first layer. A process of producing the at least partially porous structure includes depositing and scanning metal powder layers. At least some of the scanned metal powder layers form either one or both of a portion of a first section of the structure and a portion of a second section of the structure formed by at least the struts defining the porous geometry.

Abstract: One embodiment of the implant comprises a porous metal bone ingrowth portion (14) having a first side connected to a high density or solid (fully dense) metal portion (16) which in turn has an opposite side connected to a porous metal soft tissue ingrowth portion (12) thus forming a sandwich structure with the high density or fully dense portion in the middle. The implant may be made of a resorbable material such as an alloy of magnesium. Alternately, the alloy can be selected from the group consisting of calcium, iron, yttrium and lithium. The porous metal soft tissue ingrowth portion (12) has porosity characteristics allowing cartilage to interdigitate with the pores and extend outwardly beyond the platform of the metal surface towards a joint capsule. The solid or fully dense intermediate layer 16 may have some porosity, however that porosity prevents either bone tissue or cartilage tissue from migrating therethrough.

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.

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.