Reticulated Mesh Arrays and Dissimilar Array Monoliths by Additive Layered Manufacturing Using Electron and Laser Beam Melting

Abstract

Compositions and methods for making a three dimensional structure comprising: designing a three-dimensional structure; melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or laser beam is described herein. The position where the metal is melted into the structure is formed along a layer of metal powder, wherein the location and intensity of the beam that strikes the metal layer is based on the three-dimensional structure and is controlled and directed by a processor. The instant invention comprises a novel dry state sonication step for removing metal powder that is not melted from the three dimensional structure.

What is claimed is: 
     
         1 . A three dimensional structure made by a method comprising:
 designing a three-dimensional structure;   melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or a laser beam, wherein the position where the metal is melted into the structure is formed along a layer of metal powder, wherein a location and an intensity of the beam striking the metal layer is based on the three-dimensional structure and is controlled and directed by a processor; and   removing the metal powder from the three-dimensional structure that is not melted with an ultrasonic device.   
     
     
         2 . The structure of  claim 1 , wherein the step of removing the metal powder further comprises the step of removing the metal powder that is not melted by sonication using the one or more ultrasonic devices, wherein the sonication is a dry sonication. 
     
     
         3 . The structure of  claim 1 , wherein the one or mole ultrasonic devices are selected from at least one of resonant probes, ultrasonic welders or high frequency sound transmission devices. 
     
     
         4 . The structure of  claim 1 , wherein the ultrasonic device is a resonant probe. 
     
     
         5 . The structure of  claim 4 , wherein the resonant probe is operated at frequencies ranging from 20 to 80 kHz. 
     
     
         6 . The structure of  claim 1 , wherein a frequency of operation of the one or more ultrasonic device is dependent on a shape, a density, and a geometry of the three-dimensional structure. 
     
     
         7 . The structure of  claim 1 , wherein the three dimensional structure comprises at least a portion that is a reticulated mesh array. 
     
     
         8 . The structure of  claim 1 , wherein the beam melts metal powder layers using electron or laser beams. 
     
     
         9 . The structure of  claim 1 , wherein the metal powder comprises Ti-6Al-4V. 
     
     
         10 . The structure of  claim 1 , wherein the metal powder comprises Co-26Cr-6Mo-0.2C. 
     
     
         11 . The structure of  claim 1 , wherein the three dimensional structure comprises at least one of a porous coating, a thin porous bead coating, a sintered mesh array, a thermal-spray coating, and a metallic foam on a medical device. 
     
     
         12 . The structure of  claim 1 , further comprising the steps of obtaining three-dimensional coordinates for a shape for tissue replacement, calculating the shape of a three-dimensional implant based on the three-dimensional coordinates of the shape for tissue replacement, and forming the three-dimensional implant. 
     
     
         13 . The structure of  claim 1 , further comprising the steps of obtaining three-dimensional coordinates for a shape for tissue replacement, calculating the shape of a three-dimensional implant based on the three-dimensional coordinates of the shape for tissue replacement, and selecting one or more metal powders to form the three-dimensional implant based on at least one of weight, mechanical strength, porosity, geometry and biocompatibility. 
     
     
         14 . The structure of  claim 1 , further comprising the step of adding one or more biocompatible polymers to the three dimensional structure. 
     
     
         15 . The structure of  claim 1 , further comprising the step of adding one or more cellular growth factors. 
     
     
         16 . The structure of  claim 1 , wherein the three dimensional structure comprises orthopedic implants, femoral stems, tibial stems, femoral rods, and combinations and modifications thereof. 
     
     
         17 . A three dimensional structure made by a method comprising:
 designing a three-dimensional structure;   melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or a laser beam, wherein the position where the metal is melted into the structure is formed along a layer of metal powder, wherein a location and an intensity of the beam striking the metal layer is based on the three-dimensional structure and is controlled and directed by a processor; and   removing the metal powder from the three-dimensional structure that is not melted with an ultrasonic device.   
     
     
         18 . A method of making a biologically compatible, three dimensional, mesh array comprising:
 designing a three-dimensional mesh array structure comprising lattice elements;   melting the three-dimensional mesh array structure from two or more layers of a biocompatible metal powder with a high energy electron beam, wherein a position where the metal is melted into the structure is formed along a layer of metal powder, wherein a location and an intensity of the beam striking the metal layer is based on the three-dimensional structure and is controlled and directed by a processor; and   removing the metal powder that is not melted by sonication with one or more ultrasonic device.   
     
     
         19 . The method of  claim 18 , wherein the step of removing the metal powder is defined further as comprising dry state sonication. 
     
     
         20 . The method of  claim 18 , wherein the beam melts metal powder layers using electron or laser beams. 
     
     
         21 . A biologically compatible, three dimensional, mesh array made by a method comprising:
 designing a three-dimensional mesh array structure comprising lattice elements;   melting the three-dimensional mesh array structure from two or more layers of a biocompatible metal powder with a high energy electron beam, wherein a position where the metal is melted into the structure is formed along a layer of metal powder, wherein a location and an intensity of the beam striking the metal layer is based on the three-dimensional structure and is controlled and directed by a processor; and   removing metal powder from the three-dimensional structure that is not melted by sonication with one or more ultrasound devices.